In-Space Servicing and Manufacturing

A new generation of spacecraft is transforming how we operate in space. Rather than treating satellites as disposable assets, in-space servicing extends their operational lives. Meanwhile, manufacturing in microgravity creates products impossible to make on Earth. Together, these capabilities represent a fundamental shift toward a sustainable space economy.

On-Orbit Servicing Overview

On-orbit servicing (OOS) encompasses a range of activities that maintain, repair, or enhance operational spacecraft. The market addresses several critical needs:

• Life extension: Adding propellant or propulsion to extend satellite operational life
• Repair: Fixing malfunctions that would otherwise end a mission
• Inspection: Close examination of spacecraft for anomaly diagnosis
• Relocation: Moving satellites to different orbital positions
• Upgrade: Adding new capabilities to existing spacecraft
• Debris removal: Capturing and deorbiting defunct objects

The economic case is compelling: a GEO communications satellite costing $300+ million to build and launch might run out of propellant with years of useful life remaining. Extending operations for $50-100 million generates significant value for operators.

Satellite Life Extension

Northrop Grumman Mission Extension Vehicle

Northrop Grumman's Mission Extension Vehicle (MEV) provides the most mature commercial life extension service. MEV-1 docked with Intelsat 901 in 2020, becoming the first commercial spacecraft to service another commercial spacecraft. MEV-2 followed with Intelsat 10-02 in 2021.

The MEV attaches to the target satellite's apogee kick motor, taking over stationkeeping and attitude control. This approach requires no modifications to the client satellite, though it does limit which spacecraft can be serviced. Northrop Grumman is developing Mission Robotic Vehicle (MRV) with greater flexibility.

Mission Robotic Vehicle

MRV improves on MEV by carrying multiple Mission Extension Pods (MEPs) that attach to client satellites independently. This allows a single MRV to service multiple spacecraft, reducing per-satellite costs. MRV also carries robotic arms for inspection and potential repair operations.

Space Debris Removal

Space debris poses an existential threat to the space industry. With over 36,000 tracked objects larger than 10 cm and millions of smaller pieces, the risk of cascading collisions (Kessler syndrome) grows with each new launch. Active debris removal (ADR) offers a solution.

Astroscale

Astroscale leads the commercial debris removal market. The Japan-founded company has demonstrated rendezvous and proximity operations with its ELSA-d mission, capturing a target satellite with a magnetic docking mechanism. ADRAS-J conducted close inspection of a defunct rocket body in 2024.

Astroscale is developing services for both prepared satellites (with docking interfaces) and non-cooperative debris. The company has partnerships with JAXA and commercial operators, working toward regular removal operations.

ClearSpace

ClearSpace, a Swiss company, won ESA's first debris removal contract. ClearSpace-1 will use a four-armed capture system to grab a Vega rocket payload adapter and deorbit it. This mission, planned for 2026, will demonstrate controlled debris removal techniques.

Business Models

Debris removal economics remain challenging. While the collective benefit of a cleaner orbital environment is clear, individual incentives are weak. Potential business models include:

• Government contracts: Space agencies paying for removal of their own debris
• Regulatory requirements: Mandating debris removal as condition of launch licenses
• Insurance incentives: Lower premiums for constellations with removal plans
• Operator services: Removing defunct competitor satellites that threaten active assets

In-Space Refueling

Orbit Fab

Orbit Fab is building infrastructure for in-space refueling. The company has developed the RAFTI interface standard for spacecraft refueling and deployed fuel depots in orbit. By enabling propellant transfer, Orbit Fab addresses the fundamental limitation of satellite operational life.

The company's Gas Stations in Space concept envisions a network of fuel depots enabling spacecraft to refuel multiple times throughout their operational lives. This could transform satellite economics and enable new mission profiles.

Technical Challenges

Propellant transfer in microgravity presents significant challenges:

• Fluid management: Without gravity, propellants don't settle predictably
• Connection systems: Reliable, leak-free coupling in orbit
• Compatibility: Different spacecraft use different propellants
• Safety: Handling hypergolic and cryogenic propellants

In-Space Manufacturing

Microgravity offers unique manufacturing advantages impossible to replicate on Earth. The absence of convection and sedimentation enables:

• Perfect crystal growth: Protein crystals for drug development, semiconductor crystals
• Uniform mixtures: Alloys and composites without density-driven separation
• Fiber drawing: ZBLAN fiber optics with dramatically reduced defects
• Bioprinting: 3D printing of tissues without gravitational collapse
• Large structures: Assembly of objects too large to launch

Varda Space Industries

Varda Space Industries achieved a major milestone in 2024 by successfully returning products manufactured in orbit. The company's autonomous spacecraft factories grow pharmaceutical crystals in microgravity, then return the capsule to Earth via controlled reentry.

Varda's focus on pharmaceuticals targets a high-value market where space manufacturing costs can be justified by improved drug efficacy. Better crystal structures can lead to more effective medications, potentially worth billions in pharmaceutical markets.

Redwire Space

Redwire Space operates manufacturing systems on the International Space Station, including 3D printers and materials processing equipment. The company acquired Made In Space, pioneers of additive manufacturing in orbit, and is developing Archinaut systems for robotic construction of large structures.

Space Forge

UK-based Space Forge is developing returnable spacecraft for manufacturing advanced semiconductors and other materials in microgravity. The company's reusable platform concept aims to make regular production flights economically viable.

On-Orbit Assembly

Some structures are too large or delicate to survive launch. On-orbit assembly enables construction of spacecraft and infrastructure that would be impossible to deliver intact.

Applications

• Large antennas: RF reflectors too large to fit in fairings
• Solar arrays: Massive power generation systems
• Space stations: Modular construction over multiple launches
• Telescopes: Segmented mirrors assembled in space

Starfish Space

Starfish Space is developing autonomous docking systems for satellite servicing. The company's Otter spacecraft demonstrates proximity operations and capture capabilities that enable inspection, repair, and repositioning of spacecraft.

Market Projections

The in-space servicing and manufacturing market is projected to grow significantly:

• Satellite servicing: $4-5 billion market potential by 2030
• Debris removal: $2-3 billion, dependent on regulatory drivers
• In-space manufacturing: $10+ billion by 2040 for high-value products

Near-term growth depends on satellite operators adopting servicing over replacement, while manufacturing requires demonstration of economically compelling products.

Government Programs

Government agencies are significant drivers of the industry:

• NASA: OSAM-1 (previously Restore-L) robotic servicing demonstration
• US Space Force: Orbital Prime debris removal program
• ESA: ClearSpace-1 and Clean Space initiatives
• JAXA: Commercial Removal of Debris Demonstration (CRD2)

Challenges and Outlook

Several challenges must be addressed for the industry to mature:

• Standardization: Common interfaces for servicing compatibility
• Regulation: Frameworks for debris ownership and liability
• Economics: Achieving costs that make services attractive
• Trust: Operators accepting rendezvous with their assets
• Technology: Reliable autonomous operations at scale

Despite challenges, the industry is transitioning from demonstration to commercial operations. As the space environment becomes more congested and asset values increase, the case for servicing and sustainable practices strengthens. The next decade will see in-space servicing become routine, while manufacturing pioneers establish the foundations of orbital industry.