Robotic push-based self-assembly of hexagonal tiles for space applications

Assembling large-scale infrastructure in space presents significant technical and logistical challenges. Traditionally, this process involves dividing complex systems into smaller modules, launching them separately, and assembling them in orbit often relying on sophisticated and costly robotic systems. This paper introduces a robotic push-based self-assembly approach to create arrays of hexagonal tiles. Such tiles and arrays are prevalent in space structures, and in particular in the upcoming space-based solar power stations (SBSP). This design reduces mechanical complexity by employing a passive “pusher” mechanism. The system enables autonomous alignment and propulsion of hexagonal tiles into desired configurations without the use of advanced robotics, offering a simple yet scalable geometric arrangement suitable for large-scale space structures. Experimental validation was performed using a low-friction test-bed (an air hockey table) to approximate microgravity conditions. Results indicate that the pusher mechanism successfully enables directional self-assembly of hexagonal tiles in a linear configuration. Building on this outcome, future work will focus on combining multiple linear arrays to form larger, scalable hexagonal assemblies for space infrastructure applications.