The Trusselator program is investigating the value proposition and technical feasibility of fabricating composite truss structures on-orbit to enable construction of high-power solar arrays, high-gain antennas, and other large spacecraft components. In the Phase I effort, we developed a number of conceptual approaches to constructing large solar arrays, identified approaches that could minimize the complexity of the system required to implement them, and performed structural analyses of the top candidates. These analyses indicate that on-orbit fabrication could enable structural mass fraction reductions of 2-5X for many-meter trusses with respect to state-of-the-art deployable mast technologies. To validate technical feasibility, we developed a detailed design for a prototype Trusselator device capable of processing Carbon Fiber/thermoplastic tape feedstock to form long continuous lengths of composite truss. We constructed a prototype, and successfully demonstrated fabrication of multi-meter lengths of truss. We then performed mechanical testing of the truss samples that demonstrated that the truss samples achieve a higher 'bending stiffness efficiency' than flight-heritage deployable truss technologies. Moreover, this superior result was accomplished using 'standard modulus' carbon fiber materials, and integration of high-modulus carbon fiber and optimization of the process is projected to enable further orders-f-magnitude improvement in structural efficiency. This structural efficiency reduces the launch mass, launch cost, and stowed volume of support structures for solar arrays, antennas, and other spacecraft components. Future work on the Trusselator will focus on minimizing its size, weight, and power as well as demonstrating reliable operation in the thermal-vac environment.
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