SpaceMaRS: Advancing in-space manufacturing for the future space economy

Experts developed roadmaps for robotic assembly, resilient materials, lunar habitats, and demonstration infrastructure to advance space manufacturing

The University of Illinois Urbana-Champaign (UIUC) reinforced its position as a national leader in space technology and innovation by hosting the Roadmap for In-Space Manufacturing of Resilient Structures Workshop at the Beckman Institute for Advanced Science and Technology on 19-20 May, 2026, sponsored by The Grainger College of Engineering and the Aerospace Engineering Department at UIUC. The workshop brought together leading researchers, programme managers, technology developers, and decision-makers from NASA, the Air Force Research Laboratory (AFRL), industry, and academia to identify the critical challenges and opportunities that will shape the future of manufacturing, assembly, and infrastructure beyond Earth. Hosted by the UIUC Center for In-Space Manufacturing of Resilient Structures (SpaceMaRS), the workshop reflects the Center’s mission to develop a fundamental understanding of the materials science-processing-property relationships that enable on-demand manufacturing of resilient, lightweight structures in space. Bringing together faculty and students from multiple departments within The Grainger College of Engineering, the Center is preparing the next generation of engineers while addressing the technical challenges of the rapidly expanding space economy. A complete workshop report is available on the Center’s website.

“By convening leaders from across government, industry, and academia, Illinois has established itself as a national hub for defining the future research agenda and technology roadmap for in-space manufacturing and resilient space infrastructure,” said Professor Jeff Baur, one of the workshop organisers and leaders of the SpaceMaRS Center. “The discussions highlighted both the transformative opportunities and the significant challenges that must be addressed to enable sustainable operations in Low Earth Orbit, on the Moon, and beyond.”

The primary objective of the workshop was to develop research and technology road maps for resilient materials and structures that support in-space and off-world servicing, assembly, and manufacturing from both fundamental and applied research perspectives. Equally important was fostering partnerships among universities, government agencies, and industry to accelerate the transition of promising technologies into operational capabilities. Throughout the workshop, participants emphasised that future space infrastructure will require integrated advances in materials, structures, robotics, qualification methodologies, autonomous systems, and demonstration infrastructure to achieve sustainable and economically viable space operations.

The workshop featured invited presentations by leaders from across NASA, AFRL, industry, and academia, which formed the basis for breakout discussions and technology roadmaps centered on four major technical themes: 1. In-Space Robotic Assembly and Manufacturing, 2. Resilient Materials and Structures for the Harsh Low Earth Orbit (LEO) Environment, 3. Structures for Off-World Habitats, and 4. Characterisation, System Integration, and Demonstration Infrastructure.

In-space robotic assembly and manufacturing

One of the motivating presentations was delivered by Professor Sameh Tawfick on Mission Illinois, in which a multidisciplinary team of Illinois researchers will demonstrate an energy-efficient chemical curing process aboard the International Space Station (ISS) for manufacturing carbon-fibre composite structures. The fabricated composite longeron is intended to serve as a fundamental building block for future large-scale space structures – including next-generation space telescopes, radio-frequency antennas, and other precision sensing systems requiring exceptional dimensional accuracy while spanning hundreds of meters. The mission is supported by the Defense Advanced Research Projects Agency’s (DARPA) Novel Orbital Moon Manufacturing, Materials, and Mass Efficient Design (NOM4D) programme and builds upon Illinois’ pioneering research in frontal polymerisation of composites.

Workshop discussions concluded that large-scale in-space manufacturing and assembly will require highly autonomous systems, qualified interfaces, robust process monitoring, and standardised manufacturing practices. Participants identified major challenges including the inability to fully validate many In-space Servicing, Assembly, and Manufacturing (ISAM) processes on Earth, the absence of common standards and qualification pathways, uncertain commercial business cases, and the limited availability of space-qualified hardware. At the same time, they highlighted significant opportunities in standardised mechanical, electrical, and data interfaces; autonomous robotic assembly; digital and physical twins; embedded sensing and monitoring systems; and lifecycle-aware design methodologies. Professor Robyn Woollands further emphasised the complexities of multi-agent robotic manufacturing, where autonomous systems must coordinate orbital mechanics, propulsion requirements, and structural interactions while assembling large structures in space. Collectively, participants envisioned an ecosystem in which autonomous robotic systems can reliably manufacture, assemble, inspect, maintain, and eventually repair large-scale infrastructure in orbit.

Resilient materials and structures for the harsh space environment

A second major workshop theme focused on understanding and mitigating the effects of the harsh space environment on materials and structures. Professor Nancy Sottos highlighted opportunities for future collaborations in space-environment simulation, materials characterisation, and data sharing from both orbital experiments and laboratory testing. Illinois researchers are uniquely positioned to connect on-orbit data from programmes such as MISSE with advanced ground-based testing, simulation, and multiscale modelling capabilities. Professor Xin Ning described unique facilities for investigating the combined effects of Atomic Oxygen (AO) and Vacuum Ultraviolet (VUV) radiation on material performance, capabilities that will both accelerate the development of new space materials and improve understanding of degradation mechanisms experienced in Low Earth Orbit. Professor Huck Beng Chew emphasised the importance of multiscale modelling to reveal how atomic- and molecular-scale interactions influence long-term degradation, while Professor Ioannis Chasiotis’ laboratory provides rare experimental capabilities for high-throughput hypervelocity impact testing that enable investigation of the combined effects of orbital debris damage and environmental degradation.

Participants identified qualification of materials under the combined effects of atomic oxygen, radiation, thermal cycling, and micrometeoroid and orbital debris (MMOD) as one of the field’s most pressing challenges. Existing ground-based simulations remain costly, inconsistent, and often unable to faithfully reproduce the LEO environment. Key opportunities include standardised testing protocols, shared qualification databases, AI-enabled prediction of long-term in-space performance from accelerated testing, embedded structural health monitoring, and autonomous repair and self-healing technologies. The long-term vision is a robust qualification framework that enables reliable design, monitoring, maintenance, and lifetime prediction of resilient space structures.

Structures for off-world habitats

Presentations from NASA researchers highlighted the growing need for mechanically and thermally resilient materials and manufacturing approaches to support future lunar habitats. Discussions identified three dominant challenges: mitigating the effects of abrasive lunar regolith, surviving the extreme thermal conditions associated with the lunar night, and developing durable, scalable construction methods suitable for long-duration human presence. Participants emphasised that future habitats would require integrated solutions combining thermal management, structural durability, site preparation, and in-situ resource utilisation. Significant opportunities were identified in the use of lunar regolith as a construction material, development of advanced insulating materials, autonomous robotic construction, and progressive demonstration missions that mature technologies from laboratory concepts to operational lunar infrastructure.

Characterisation, system integration, and demonstration infrastructure

Presentations from industry leaders focused on enabling launch and payload capabilities beyond the International Space Station to meet the growing commercial and government demand for in-space technology demonstrations. Discussions emphasised the need for increased launch capacity, lower launch costs, and expanded access to orbital demonstration platforms. The Grainger College of Engineering Executive Associate Dean Philippe Geubelle noted that the strong participation from NASA, AFRL, commercial space companies, and academic leaders underscored the importance of a coordinated, multidisciplinary approach. Jonathan Volk, Business Development Director at Voyager Technologies, described the company’s commitment to enabling academic and government research through access to commercial space-based testing and demonstration opportunities. With the planned Starlab commercial space station intended to succeed the ISS, partnerships between academia, government, and industry will play an increasingly important role in transitioning emerging technologies from laboratory research to operational space systems.

A recurring theme throughout the workshop was the need for practical demonstration and qualification pathways. Participants identified high launch costs, lengthy development cycles, regulatory complexity, workforce limitations, and insufficient logistics infrastructure as significant barriers to widespread adoption of ISAM technologies. Opportunities include expanding CubeSat and hosted-payload demonstrations, establishing common interface standards, developing workforce training programmes, and creating commercially operated orbital testbeds. Long-term success will ultimately depend on a mature space logistics infrastructure, routine access to demonstration opportunities, and coordinated international participation that supports a sustainable and commercially viable space manufacturing ecosystem.

Conclusion

The workshop established a comprehensive set of technology roadmaps identifying near-, mid-, and long-term priorities spanning resilient materials, off-world habitats, robotic manufacturing, qualification methodologies, and demonstration infrastructure. If these recommendations are realised, we envision a future in which today’s paradigm of bespoke deployable space systems – limited in size, durability, and operational life – is replaced by agile in-space manufacturing of large, resilient structures, enabled by declining launch costs and the rapidly growing demand for space-based infrastructure and services.

A summary of the workshop findings is available on the Illinois Center for In-Space Manufacturing of Resilient Structures website. Participants concluded that sustained collaboration among universities, government laboratories, industry, and space agencies will be essential to transform emerging in-space manufacturing technologies into operational capabilities that support future space exploration, commercial development, and a sustained human presence beyond Earth.

Please note, this article will also appear in the 27th edition of our quarterly publication.