In-Space Assembly of Structural Trusses and Shapes

The NASA innovation is based on a tessellation algorithm to break up a curved surface into identically sized equilateral surface polygons. Tessellation is a term used in mathematics that describes the process of deconstructing a surface into non-overlapping shapes with no gaps. Using this NASA innovation enables a curved-surface truss structure to be designed and built using all identical module and strut components. A key feature of this innovation is the use of a “multi-nut” connector, which enables curved surface truss structures to be assembled from identical truss modules. Uniform truss modules with customizable multi-nut connectors can be used to construct a curved-surface structure. The algorithm is a design approach for any size or surface shape. The NASA innovation represents a major breakthrough due to: • Versatility to a variety of planar and curved structure shapes (cylinder, sphere, etc.) • Ability to change the shape simply by updating the “multi-nut” connectors • Commonality of truss modules and components • Ease of assembly • Efficiency of construction and weight • Robotic assembly and servicing. In addition to a range of space related applications – mirrors, antennas, habitats, storage containers, etc. – the innovation is also directly applicable to general terrestrial assembly of systems with curvature, including for example sports stadiums, airports, aquariums, convention centers, or bridges. NASA engineers have developed an innovative method for simple design and modular assembly of curved, double-curved, or flat structures in space or on earth or lunar surfaces. The approach is expected to have greatest utility in structures ranging from a few meters to 100’s of meters. Most current space structures are launched as a single monolithic or deployable unit and are thus limited by the mass and volume constraints. In-space assembly of modular components delivered from one or more launches is an alternative approach. However, curved structures typically are separated into many unique components which greatly complicates manufacturing and assembly. This novel technology introduces a new design that localizes the differences between truss modules to a small, easily fabricated connector. Thus, the majority of the module, even for curved surfaces, can be standardized to simplify fabrication, testing, and subsequent assembly at the destination.