Orbital Robotic Construction System for Large-scale Space Stations (in progress)

CLIENT: Offworld Industries Corporation

CONCEPT: The SARGON orbital construction system uses a ring of magazine / cassettes to dispense stacks of panels sequentially into a ring, which is later welded into place after tolerance / accuracy measurements. A series of modular trusses have rails for robotic material handling carts to deliver stacks of panels between a 'materials tree' supply ship and the magazine ring. The trusses act as scaffolding and jig structure to keep the large-scale assembly true and accurate. All construction site materials, assembly equipment, and constructed portions are mechanically connected using solid frames and connections to manage all parts and equipment in the same orbit. Booster spacecraft and attitude control system maintain the orbit.

DESIGN TEAM: Original SARGON concept with magazine panel assemblers by John Blincow. Robotic construction site and assembly line configurations designed by A. Scott Howe. Other team members include Colin Leonard and Theodore W. Hall.

COST: TBA.

DATE: 2025.

STATUS: Studies continue as of this writing.

In Figure 1 (from Howe, Blincow, Hall, & Leonard 2025) shows six major steps for constructing large-scale orbital space station pressure hulls: 1) 'materials tree' is delivered by SpaceX Starship or equivalent; 2) small robotic or crewed manipulator craft retrieves panel stack from 'materials tree'; 3) manipulator craft carrying panel stack; 4) approaching panel magazine / cassette at construction site; 5) insertion of panel stack into magazine / cassette; 6) assembly of panel into torus structure.