Supporting in-space manufacturing via nondestructive evaluation

Manufacturing satellites directly in space offers enhanced flexibility and faster responses to mission demands. Structural components can be created using printed polymers as they do not need to withstand launch loads. Hybrid additive manufacturing could integrate printed circuits and pre-made modules, such as solar cells, into host structures. Adhesive bonding is a likely candidate for assembly. However, adhesive bonding is vulnerable to stress-induced failures due to thermal cycling, and long-term degradation factors like radiation damage. Coupled with manufacturing challenges, such as outgassing, require reliable and robust nondestructive evaluation for mission success. For this purpose, two thoroughly tested NDE methods are taken into consideration: guided wave-based ultrasonics and infrared thermography. Specifically, the implementation of both technologies under size, weight and power constraints, are considered. Ground-based testing establishes a baseline for future space missions, in an effort to ultimately ensure the integrity of joints bonded in the harsh space environment.