The Grainger College of Engineering at the University of Illinois Urbana-Champaign has established the Centre for In-Space Manufacturing of Resilient Structures (SpaceMaRS) to advance on-orbit production and assembly of durable space structures.
The initiative builds on DARPA-supported research demonstrating that carbon fibre composites can be manufactured in space and assembled robotically, eliminating the need to launch pre-made components.
SpaceMaRS leverages ongoing Air Force Office of Scientific Research programmes on composites that are resistant to micrometeoroid impacts, atomic oxygen, and ultraviolet radiation. Facilities include a large-scale 3D printer for continuous fibre composites, simulated Low Earth Orbit chambers, and a hypervelocity two-stage light-gas gun.
The DARPA-backed Mission ‘Illinois’, scheduled for the International Space Station in 2026, will test on-orbit curing of pre-impregnated carbon fibre composites using a heat-triggered chemical reaction. Prof Sameh Tawfick, who is leading the project, highlighted its potential for building complex structures, such as orbital data centres.
In parallel, Prof Jeff Baur’s research focuses on ensuring the structural resilience of space composites using advanced chemistries and AI-assisted damage monitoring.
Organised by Prof Ioannis Chasiotis, SpaceMaRS brings together eight faculty members across four departments, integrating expertise in space environment simulation, robotics, composites, multifunctional structures, and materials modelling, positioning Illinois as a leader in next-generation space manufacturing.
