Manufacturing
Due to speed of light constraints on communication, manufacturing in space at a distant point of resource acquisition will either require completely autonomous robotics to perform the labor, or a human crew with all the accompanying habitat and safety requirements. If the plant is built in orbit around the Earth, or near a manned space habitat, however, telecheric devices can be used for certain tasks that require human intelligence and flexibility.
Solar power provides a readily available power source for thermal processing. Even with heat alone, simple thermally-fused materials can be used for basic construction of stable structures. Bulk soil from the Moon or asteroids has a very low water content, and when melted to form glassy materials is very durable. These simple, glassy solids can be used for the assembly of habitats on the surface of the Moon or elsewhere. The solar energy can be concentrated in the manufacturing area using an array of steerable mirrors.
The availability and favorable physical properties of metals will make them a major component of space manufacturing. Most of the metal handling techniques used on Earth can also be adopted for space manufacturing, but a few will need significant modifications. The microgravity environment of space will necessitate modifications to some metal handling techniques.
The production of hardened steel in space will introduce some new factors. Carbon only appears in small proportions in lunar surface materials and will need to be delivered from elsewhere. Waste materials carried by humans from the Earth is one possible source, as are comets. The water normally used to quench steel will also be in short supply, and require strong agitation.
Casting steel can be a difficult process in microgravity, requiring special heating and injection processes, or spin forming. Heating can be performed using sunlight combined with electrical heaters. The casting process would also need to be managed to avoid the formation of voids as the steel cools and shrinks.
Various metal-working techniques can be used to shape the metal into the desired form. The standard methods are casting, drawing, forging, machining, rolling, and welding. Both rolling and drawing metals require heating and subsequent cooling. Forging and extrusion can require powered presses, as gravity is not available. Electron beam welding has already been demonstrated on board the Skylab, and will probably be the method of choice in space. Machining operations can require precision tools which will need to be imported from the Earth for some duration.
New space manufacturing technologies are being studied at places such as Marshall's National Center for Advanced Manufacturing. The methods being investigated include coatings that can be sprayed on surfaces in space using a combination of heat and kinetic energy, and electron beam free form fabrication of parts. Approaches such as these, as well as examination of material properties that can be investigated in an orbiting laboratory, will be studied on the International Space Station.
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