Simulating the Dynamics and Control of a Free-Flying Small Satellite with a Robotic Manipulator for 3D Printing

Abstract

On-orbit manufacturing is an emerging concept that offers several benefits when compared with traditional space structures that are built on the ground and launched fully assembled. Structures manufactured in space are not limited by launch vehicle fairing volumes and do not require reinforced structures needed to survive the ascent to orbit. Additive manufacturing is uniquely suited to this paradigm and has been proposed as a key piece of several on-orbit manufacturing architectures. However, the complex dynamics involved with 3D printing a structure on-orbit require additional study. Controlling a spacecraft with a robot arm is a complicated problem and additive manufacturing is especially difficult due to the large tool paths required to complete a structure. Here a numerical model of a free-flying small satellite with a robotic arm assembly is presented. Simulation results are presented with examples of structures 3D printed on-orbit and analysis of the impacts the robotic arm movements have on the control of the small satellite. Multiple control strategies are implemented with resource utilization tracked throughout the simulation. The results of the simulation can be used to inform the design of future small satellite systems attempting complicated on-orbit manufacturing missions.