Final Results

Significant achievements in WP2 include a thorough market analysis identifying new opportunities for On-Orbit Services (OOS) and In-Space Manufacturing and Assembly (ISMA), as well as a detailed system requirement and concept definition for ORU-BOAS. These efforts established the groundwork for defining mission requirements, concept of operations, and technology readiness goals. The progress was validated in the successfully held System Requirements Review (SRR). Key results from WP2 include:

• Market and Economic Studies: TAS I led the analysis of market trends, identifying key growth areas within OOS and ISMA, along with specific use cases for the ORU-BOAS as a construction unit for modular satellites. This research underscores ORU-BOAS’s potential in evolving space markets, including potential configurations beyond the Horizon Europe IOD.
• AppStore Concept Exploration: The AppStore concept for payload selection and modular platform design was examined, emphasizing benefits like flexibility, adaptability, and a broader choice of payloads for potential users.
• Preliminary Concept and System Definition: an initial demonstration and operational concept was defined, including the mission concept and the associated requirements for new system concepts, which provide a roadmap for the ORU-BOAS's design and functionality.
• IOD Mission Requirements and Gap Analysis: TAS F identified requirements specific to the IOD scenario, particularly for interfaces, environmental tolerances, and loads. A gap analysis between IOD needs and the current ORU-BOAS design highlighted areas needing further refinement.
• System and Verification Engineering: The consortium conducted a technology readiness assessment, of the designs and established a validation and control plan for ORU-BOAS. Each partner’s subsystem responsibilities were decided, setting the foundation for collaborative progress.

Most Important Result: Establishing a clear, detailed requirement and concept definition that aligns ORU-BOAS with both market demands and technical expectations. This framework ensures that the projects develops a product that meets the demands of future missions.

REDEFINING THE STATE-OF-THE-ART

WP2’s findings introduce a new level of modularity and flexibility to on-orbit services and assembly systems. The integration of a modular, AppStore-driven ORU unit enables a plug-and-play approach to satellite assembly and maintenance, a departure from current, rigid space hardware designs. These advancements will reduce mission costs and open new market possibilities by allowing adaptable, reusable systems that support various payloads and mission scenarios.

WP3 focuses on advancing the ORU-BOAS concept from the initial requirements defined in WP2 to a preliminary design. This includes the first designs of key modules and components like the ORU platform and payloads, each substantiated with trade-off analyses, justifications, and technical budgets. Additionally, WP3 sets the foundation for the DSSCK (Design and Development Specification for Satellite Construction Kit), essential for future modular spacecraft assembly and operations. Everything was reviewed in the successfully held Preliminary Design Review (PDR).

The main accomplishments of WP3 focus on advancing the ORU-BOAS from concept to preliminary design:

• Preliminary Design Review (PDR): Successfully completed the PDR in Brussels, where initial designs were rigorously evaluated. Feedback from external experts helped refine the ORU concept, ensuring compatibility with both On-Orbit Servicing (OOS) and In-Space Manufacturing and Assembly (ISMA) scenarios.
• Design and Development Specification for Satellite Construction Kit (DSSCK): Established foundational requirements for a modular kit that will allow ORU-BOAS and future space modules to integrate seamlessly for in-orbit servicing and assembly, setting a framework for modular spacecraft design.
• ORU Platform Design: Developed a scalable ORU platform compatible with multiple interfaces such as SIROM, designed for payload interchangeability, and equipped with an AppStore model to support diverse missions.
• Standard Interface (SI): Designed a preliminary SI for effective module communication, attachment and docking, capable of supporting diverse mission requirements and enhancing modularity.
• Subsystem Integration: Consolidated key subsystems, including the sMart Integrated Avionics (MIA) for reliable commanding and data flow among modules, and the IMEPS3 modular power system, ensuring compatibility with a variety of mission requirements.
• Preliminary Testing Plan: Defined an initial breadboard test plan to assess critical ORU functionalities, including module interchangeability, data and power transfer, and docking maneuvers.

The successful completion of the PDR stands as a major milestone, marking the validation of our preliminary designs by external experts. Additionally, establishing the DSSCK as a modular framework for future missions represents an innovative step forward, setting the foundation for modularity in space infrastructure that can accommodate diverse mission needs.

REDEFINING THE STATE-OF-THE-ART

WP3’s findings contribute to a shift from traditional single-use satellite designs to a flexible, modular architecture. The ORU-BOAS system addresses the need for in-space construction, servicing, and decommissioning by creating plug-and-play modules that can be assembled, replaced, or upgraded in orbit. This approach reduces launch costs, extends mission life, and enhances adaptability, addressing the evolving needs of space missions.

WP4 marked a crucial phase in the ORU-BOAS project, concluding the system’s detailed design and achieving significant progress toward manufacturing and testing. Following the Preliminary Design Review (PDR) under WP3, the Critical Design Review (CDR) in April provided essential validation of the system’s detailed design by external experts. After WP4, the project moved toward its final objectives, with hardware manufacturing and testing.

During WP4, the ORU-BOAS project advanced from preliminary design to fully detailed design. Major achievements include:

• Market and Economic Study Update: Building on WP2, this update recognized new potential markets beyond GEO, especially for LEO applications, refining the exploitation plan to broaden ORU-BOAS’s market applicability.
• Critical Design Review (CDR): Held in April in Brussels, this significant milestone evaluated and validated the detailed system design. External experts assessed the progress, affirming the system's feasibility and alignment with project goals.
• Detailed Platform and Subsystem Design: The design of key components such as the Data Handling System (MIA), power system (IMEPS3), high power energy system (HPES) and standard interface (SIROM) were finalized.
• ORU BOAS Test Plan Consolidation: Comprehensive interface definitions allowed for the establishment of the ORU BOAS Test Plan, setting the stage for the Manufacturing Readiness Review (MRR). This process enabled the subsequent manufacturing and hardware preparation phase for testing.

The successful completion of the Critical Design Review (CDR) and the establishment of the ORU BOAS Test Plan stand out as key achievements. The CDR milestone confirmed the technical robustness of the detailed design, setting a strong foundation for hardware manufacturing and final testing phases.

REDEFINING THE STATE-OF-THE-ART

WP4 advances the state-of-the-art in modular space systems through its standardized design approach, offering flexible, interoperable modules for space applications. The standardized interface and modular design allow for seamless integration with various systems, contributing to cost-effective, scalable, and adaptable solutions in orbital servicing and assembly.

WP5 focuses on defining and manufacturing the breadboards necessary to validate the ORU-BOAS designs, and on the preparation of the validation phase. The primary milestones for this phase were the successful completion of both Manufacturing Readiness Review (MRR) and Test Readiness Review (TRR), ensuring the project's readiness for module breadboard production and integration testing and subsequent functional testing.

The major achievements within WP5 include:

• Development of MAIT Flowchart: A comprehensive Manufacturing, Assembly, Integration, and Testing (MAIT) flowchart was defined to guide the entire breadboard manufacturing and integration process. This flowchart ensures that each step (from manufacturing to delivery) is properly planned and executed to meet the project’s testing and validation requirements.
• Successful Manufacturing Readiness Review (MRR): In May 2024, WP5 achieved a significant milestone with the successful completion of the MRR. This review validated the manufacturing processes and documentation required to proceed with the breadboard manufacturing phase. The detailed manufacturing plan includes necessary steps for module breadboard production and test preparation.
• Breadboard Manufacturing and Assembly: Breadboards for key components, including the high-power energy storage payload, ORU platform, SIROM interface, and the Data Handling System (DHS), have been manufactured. These modules have been assembled for integration testing, ensuring that each component adheres to the required specifications and is ready for functional validation.
• Finalization of Functional Test Definitions: Detailed definitions for functional testing at both ORU and payload levels have been established. The tests for ORU include attachment simulations under free-flying conditions and payload health checks, while the payload functional tests ensure the payload’s readiness for space integration.
• Successful Test Readiness Review (TRR): In October 2024, WP5 had a second milestone. This review validated the laid test procedures.

The completion of the MRR and TRR and the establishment of the detailed manufacturing and testing protocols are major achievements in WP5. These milestones confirm the project’s readiness for the final testing phase.

REDEFINING THE STATE-OF-THE-ART

WP5 ensures that the ORU platform and its components are manufactured and tested to meet space mission requirements, enhancing the interoperability, reliability, and autonomy of modular spacecraft systems.

WP6 focuses on validating the performance of the ORU-BOAS system at both the ORU and payload levels. Key achievements include simulating free-flying conditions, and demonstrating the system’s functionality, including module attachment and interchangeability.

During WP6, significant progress has been made towards validating the ORU-BOAS platform’s readiness for in-orbit demonstration:

• Functional Test Validation at Payload Level: A series of functional tests were executed to validate the performance of payload modules. These tests ensured that the payloads met the necessary requirements and functionalities for the next phase of testing at the ORU level. This step was crucial to reducing risks before the more complex ORU tests began.
• Functional Test Validation at ORU Level: The functional testing at the ORU level included key tasks like:
  • Module Attachment Validation: Testing validated the attachment mechanism using SIROM.
  • Rendezvous manoeuvres Simulation: The system was subjected to simulated orbital conditions, which is critical for ensuring that the modules could autonomously dock under realistic space conditions. The contribution of DLR is to replicate the orbital environment on ground (0-g conditions) to perform rendezvous and docking manoeuvres between ORUs. In particular, the scenario to be simulated is the docking of two ORU-AUT, which have autonomous control.
  • Interchangeability Testing: The ability to interchange modules with a robotic arm was verified, ensuring that ORUs can be easily swapped or replaced in space.
• Health Check and Functional Verifications: Health checks were performed at both the payload and ORU levels to ensure the integrity of the system. These tests confirmed that the modules could operate as intended.

Final Documentation and Result Exploitation: After completing the tests, the team worked on analyzing the results and drafting the final project documentation. This included updating the Market and Economic Studies Review, refining the TRL assessment, and preparing a roadmap for future system upgrades leading up to the IOD mission. This final documentation is critical for the project’s future steps and for securing further development funding.

The successful demonstration of module attachment and interchangeability in simulated space conditions is a critical milestone. The ability to validate these functions under realistic scenarios significantly de-risks future missions and showcases the potential of modular systems for in-orbit assembly.

The tests performed during WP6 have been crucial for preparing the ORU-BOAS platform for future in-orbit demonstration missions. The updated documentation, including the TRL assessment and Market & Economic Studies Review, will be made available to stakeholders, offering valuable insights into the project’s impact and potential for commercialization. Future publications, reports, and presentations will highlight the outcomes of these final tests.

REDEFINING THE STATE-OF-THE-ART

WP6’s activities have significantly advanced the field of modular space systems. The integration and validation of a system like ORU-BOAS, which allows for autonomous module interchangeability provide a major step forward regarding modular satellite technologies. These innovations will enable more flexible, adaptable, and cost-effective solutions for future space missions, reducing reliance on traditional, fixed spacecraft configurations.