In-Orbit Metal Forming Breakthrough

Image from UF

What Happened

On June 25, 2025, the University of Florida announced that its engineering and materials science team, in collaboration with DARPA and NASA's Marshall Space Flight Center is working on a project called NOM4D, Novel Orbital and Moon Manufacturing, Materials, and Mass-efficient Design, that leverages laser technology to create large metal structures in orbit.

University of Florida News

The process involves bending and shaping metal sheets in place with laser tracing in microgravity for the creation of large arrays, satellites, or station modules without launching full assemblies from Earth. According to the team, in-orbit forming is key because of the weight and size limits imposed by rockets.

Why It Matters for Aerospace Mechanical & Structure Applications

Mechanically, building big structural components in orbit instead of launching them fully assembled changes how aerospace systems are designed, assembled, and maintained. For mechanisms like deployable solar arrays, space station trusses, or large antenna reflectors, in-orbit laser forming allows bespoke shapes and sizes that fit the mission, rather than the launch fairing. The capability improves the flexibility of design in mechanical systems and reduces mass and cost constraints with terrestrial manufacturing and launch.

Key Implications and Takeaways

First, adopting on-orbit forming means aerospace engineers must rethink design for manufacturing in space rather than on Earth. Second, the use of laser bending in vacuum and microgravity presents a number of mechanical issues like heat dissipation, residual stresses, and dimensional control. Third, success with such forming techniques will enable new aerospace mechanisms and structural forms: bigger, lighter, and reconfigurable assemblies in orbit or beyond.