Opterus

During Phase 1, program performers are tasked to meet stringent structural efficiency targets supporting a megawatt-class solar array.
In Phase 2, teams are tasked to increase mass efficiency and demonstrate precision manufacturing for radio frequency (RF) reflectors. In the final phase, performers are tasked to demonstrate precision for infrared (IR) reflectors.

Tubular Truss Additive Manufacturing (TTAM)

Opterus is developing the Tubular Truss Additive Manufacturing (TTAM) architecture. In a patent pending process, TTAM uses collapsible tubular masts (CTMs) to fabricate high performance trusses in lengths exceeding 1 kilometer. Key features of the technology are structural mass efficiency, volumetric efficiency, high dimensional stability, rapid low energy in-space fabrication, and reusability. TTAM trusses are expected to be 10 times lighter weight that current state of the art deployable structures because:

CTMs for TTAM are low-cost roll-to-roll pultruded booms that can be flattened and roll stowed for extreme volumetric efficiency; the CTM feed stock for a 100m truss is expected to occupy less than 1 ft3 volume.

TTAM’s baseline fastening approach is a custom mechanical fastener that is readily installed and also removable to enable structure reuse and recycling. The fastener also provides an attachment point for payloads and utilities. The TTAM architecture does not use heat or time dependent curing processes; the CTMs are deformed elastically and the fasteners are mechanical features.

As a result, in space manufacturing can proceed at a high speed and with very low energy input. Truss fabrication rates on the order of meters per hour are expected.

Tensioned Precision Structures (TPS)

Opterus is developing Tensioned Precision Structures (TPS) to achieve extremely high structural mass efficiency and resiliency apertures manufactured in space. TPSs use tension, not structural depth, to achieve dimensional stability. As a result, they minimize thermal deformations while achieving a very simple architecture. The basic architecture is a circular ring truss that tensions a network of cables within the ring. The cable network forms an effective membrane reference surface of extremely low mass and high precision.

The tensioned disc architecture is a compromise between resiliency, simplicity and mass efficiency and results from decades of experience solving the challenges of large space structures. With TPS, the ring truss is first fabricated in orbit bay by bay using Opterus’ patent pending TTAM architecture until a full ring is formed. Second, the cable network will be installed. Installation is notionally performed by autonomous robotic spacecraft that move along the ring truss and fastens cables to attachment points. The operational surface is then attached to the cable network. Where parabolic surfaces are needed, stand-offs are installed to actively shape the surface.

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