Over the first 18 months of the STARFAB project, the consortium has demonstrated technical progress across all contributing partners. Space Applications Services (SPACEAPPS) played a central coordinating and technical role, leading the conceptualization of mission scenarios, functional requirement definitions, and the design of key robotic elements such as the Walking Manipulator and associated tools. SPACEAPPS also led the adaptation of the robotic system architecture and co-developed the MIM torso with UNIYORK, contributing to the warehouse layout and integration scenarios. SONACA focused on the structural design of the warehouse units and ORUs, performing trade-offs between monolithic, deployable, and truss configurations. It defined the plate-based structural approach for launch compatibility and performed resonance and stress analyses, helping to refine both primary and secondary unit designs, including interface standardization. Thales Alenia Space France (TASF) led the development of high-level architecture and concept of operations, including detailed scenario-based functional breakdowns for warehousing, assembly, and manufacturing in orbit. They defined the operational flow from launch to disposal and evaluated multiple orbital structure concepts to support the STARFAB station. Fraunhofer IML (FIML) brought terrestrial warehouse automation expertise, adapting it for the space environment by designing the rail-shuttle transport system, optimizing ORU handling mechanisms, and modeling the Car Tower and Bat Storage units. FIML's work enabled integration of automation within the station's structural modules and helped refine the ORU storage strategy. The University of York (UNIYORK) was responsible for the design and development of the Mobile Inspection Module (MIM), including mechanical, electrical, and software subsystems. UNIYORK carried out sensor integration work, developed a modular sensing enclosure with thermal and visual inspection capabilities, and established ROS2-based communication and control systems.
WP1: Concept of Operations and Requirements Consolidation
This work package laid the foundation for the STARFAB project by defining the mission scenarios and establishing the system-level Concept of Operations (CONOPS). The consortium developed three key scenarios: satellite servicing and refueling, in-orbit assembly of a large telescope, and in-orbit manufacturing of space infrastructure. SPACEAPPS led the requirement elicitation process, ensuring alignment with both flight and demonstrator systems. TASF led the scenario analysis and contributed significantly to the CONOPS documentation. SONACA, FIML, and UNIYORK provided critical input, particularly in defining robotic inspection and maintenance requirements.
WP2: Warehouse Unit Concept and Preliminary Design
WP2 focused on the conceptual and preliminary design of the orbital warehouse. SPACEAPPS contributed to the adaptation of the Walking Manipulator and the development of robotic tools. SONACA led the structural design of the primary and secondary units, evaluating monolithic and deployable structures and selecting a circular design for secondary units due to launcher constraints. FIML applied terrestrial warehouse expertise to space applications, leading the development of the Car Tower and Bat Storage concepts. UNIYORK defined the Mobile Inspection Module (MIM), including its operations, tooling, and inspection capabilities. TASF led the system-level analysis.
WP3: Critical Technologies Design and Maturation
This WP advanced the technical maturity of key components. SPACEAPPS led the WP and focused on refining the Walking Manipulator, robotic joints, and tool systems. SONACA finalized the structural design of the primary and secondary units, selecting a plate-based concept for the primary unit to meet launch vibration requirements. FIML developed the warehouse automation system, including shuttles and rail systems, and addressed integration challenges. UNIYORK matured the MIM hardware and software, finalizing sensor selection and system architecture.
WP4: Ground Demonstrator Design and MAIT
WP4 is focused on designing and preparing the ground-based demonstrator. SPACEAPPS led the WP, initiating procurement and design of key components such as the Walking Manipulator, HOTDOCK, and control systems. SONACA contributed to the breadboard design and material sourcing. FIML worked on integrating automation technologies into the demonstrator, ensuring alignment with warehouse structures. UNIYORK fabricated and tested MIM prototypes and hosted a design review meeting.
WP5: Integration, Validation and Demonstration
This work package has not yet started and is scheduled to begin at Month 22. It will focus on integrating the developed technologies and validating them through the ground demonstrator.
