UF and NASA Team Up to Bend Metal in Space—No Tools Required
As humanity prepares to venture deeper into space, one major hurdle remains: how to construct large-scale structures in orbit without the inefficiencies imposed by current launch constraints. At the University of Florida, Dr. Victoria Miller and her team have begun to tackle this challenge by developing laser-based metal manufacturing techniques designed for use in microgravity.
The Challenge of In-Space Construction
Transporting bulky structures like solar arrays or telescope frames from Earth is both costly and impractical. Instead, the UF team is working on a novel method—laser forming—that allows thin metal sheets to be precisely bent or shaped using targeted heat, rather than mechanical force. This approach avoids the need for heavy launching hardware.
NOM4D: Pioneering Orbital Manufacturing
The initiative, named NOM4D (Novel Orbital and Moon Manufacturing, Materials, and Mass-efficient Design), receives funding from DARPA and NASA. Its goal is to demonstrate that laser-forming techniques can be used in orbit to assemble components, such as a potential 100-meter antenna or solar array directly in space.
How Laser Forming Works
In this process:
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A high-powered laser beam traces precise patterns on a metal workpiece.
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Localized thermal expansion and contraction cause the metal to bend incrementally.
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Successive passes accumulate the desired global curvature.
This method eliminates the need for bulky thrusters or heavy bending tools and adapts dynamically to component shape needs.
Materials and Mechanical Integrity
Key technical questions remain around material properties:
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Can the mechanical strength and toughness of aluminum, stainless steel, or ceramic alloys be preserved after laser bending?
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How does microgravity affect the heat dissipation and bending process?
To investigate, the team performs controlled experiments on various metals, measuring parameters like temperature, curvature, tensile strength, and microstructure changes.
Extending to Space-like Testing
UF’s partnership with NASA’s Marshall Space Flight Center allows the team to test laser forming in a thermal vacuum chamber that simulates microgravity, vacuum, and thermally extreme environments. During these trials, feedback sensors track bending angles in real time to adjust laser input dynamically.
Towards True In-Orbit Manufacturing
Initial lab tests began in 2021; the project extends into mid-2026. Each iteration refines thermal models and process controls to improve accuracy and material integrity. The final phase will determine whether the laser-forming method can withstand the rigors of space, potentially revolutionizing how satellites, habitats, and infrastructure are built above Earth.
Why It Matters for Space Engineers: Reduced Launch Mass & Volume: Structures can be stowed flat and formed on orbit, drastically cutting launch cost.
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On-Demand Fabrication: Repair, replacement, or customization becomes possible without resupply missions.
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Expandable Infrastructure: Solar arrays, trusses, antennas, and even habitat units could be “grown” in space.
As the space industry moves toward greater autonomy and sustainability, laser-driven manufacturing could become a foundational tool—enabling the assembly of large-scale systems where they’re needed: in orbit and beyond.
About the Authors:
Dr. Victoria Miller leads the NOM4D project in UF’s Dept. of Materials Science & Engineering. Her PhD researcher team—including Tianchen Wei and Nathan Fripp—is focused on expanding in-situ manufacturing capabilities for orbital and lunar environments.
Original Story: From classroom to cosmos: Students aim to build big things in space News | University of Florida
