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A classic scene from several high sci-fi movies and shows is when the characters approach their new spaceship in space for the first time. It is typically attached to a massive structure \u2013 think of the Kuat Drive Yards in Star Wars or the Utopia Planitia Fleet Yards around Mars in Star Trek. These gigantic structures play a role akin to what dry docks do for modern navies \u2013 they allow for the construction of ships in a relatively controlled environment with access to tools and equipment specialized for their construction. That is the idea behind a new NASA Institute for Advanced Concepts (NIAC) grant to ThinkOrbital, a company specializing in In-space assembly, manufacturing, and construction (ISAM&C). Their idea is to build a \u201cConstruction Assembly Destination\u201d in orbit to build spacecraft in space.<\/p>\n
<\/p>\n That might seem like a lofty goal, but ThinkOrbital has some pedigree in doing ISAM&C tasks that no one else has done before. In May 2024, they launched and successfully tested the first-ever weld in space. The mission flew on a Falcon 9, spot-welded together some quarter-inch pieces of aluminum, and returned it to Earth, where the welds were closely examined.<\/p>\n They used a method called electron beam welding, which has several advantages for use in space. First, it doesn\u2019t require as much power as a traditional arc welder\u2014only around 2KW, equivalent to a household iron. Second, it doesn\u2019t create a lot of heat, which can degrade the metal being welded and cause issues like splintering, which can become dangerous in zero-gravity situations.<\/p>\n \n