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8 A European project has developed an autonomous robot that can construct large systems in space (writes Nick Flaherty). There are three demonstrators for the EU-funded Prototype of an Ultra Large Structure Assembly Robot (Pulsar) project, including an autonomous system that could construct the primary mirror of a telescope in orbit from separate parts. The system paves the way for assembling giant telescopes directly in space – those that would be too big to launch into orbit in a single piece – as well as other large space structures such as orbiting solar panels or solar sails. The Pulsar project is headed by French firm Magellium and includes seven other European organisations. The high- precision autonomous robotic system demonstrator can build a 1:3 scale mirror (300 x 180 mm) consisting of six tiles weighing 11 kg each. In the demonstrator, each tile is covered with a transparent plate, but under real-world conditions they would be equipped with a mirror. “In the future, we will be able to assemble a 35 m-diameter mirror with many more tiles,” said Julien Rouvinet, a senior engineer at Swiss research lab and project partner CSEM. “But it doesn’t make much sense for us to build a demonstrator on this scale, as the weight of this structure would be a major problem on Earth, although of course, in orbit the weight of this structure would not be a problem.” The demonstrator includes a robotic arm that connects six components together and operates them. CSEM custom- designed the six tiles, including two with tripods to enable them to adjust their positions with a precision of 1 micron and a repeatability better than 5 microns. The tripods can achieve such accuracy thanks to the use of 3D-printed flexible joints, a first in this kind of space application. “The joints prevent the system’s components from rubbing against each other and wearing out, eliminating the need for lubricant,” said Rouvinet. “That means the system can operate for longer and deliver enhanced precision.” The software used to control and calibrate the system was also developed by CSEM engineers. “This system could be used for other purposes as well, such as to repair satellites, refuel space stations, assemble solar panels or even build huge heat shields for missions to land on Mars,” said Rouvinet. Space vehicles In-orbit systems builder February/March 2022 | Unmanned Systems Technology It could be used for other purposes as well, such as to repair satellites, refuel space stations or build huge heat shields for Mars missions Platform one The Pulsar project paves the way for assembling giant telescopes in space