There are 6,500 satellites in orbit, but only about half of them are functional. Once a satellite breaks down or runs out of fuel, it is essentially useless. Repairs, maintenance and upgrades are nearly impossible in orbit.

It's launch once, use once.

But as satellites have become more robust, their operators often find that fleets outlast their projected lifespans and need new technology, repairs, refueling or maintenance to stay competitive, relevant and operational.

Researchers from Carnegie Mellon University will head a consortium selected by the Air Force Research Laboratory (AFRL) and the Air Force Office of Scientific Research (AFOSR) to pioneer research into robotic inspection, maintenance and manufacturing of satellites and other structures while in orbit. Led by principal investigator Howie Choset(opens in new window) (left), CMU will collaborate with researchers at the University of New Mexico, Texas A&M, and Northrop Grumman Corporation to develop systems for intelligent inspection, dexterous maintenance and agile manufacturing of satellites in space.

"This is an incredible opportunity to work together toward an ambitious goal," said Choset, a professor in the Robotics Institute(opens in new window) at CMU's School of Computer Science(opens in new window). "No one knows how to refuel spacecraft such as satellites and telescopes. If we're successful, we will."

The work will require expertise in artificial intelligence, hard and soft robotics, additive manufacturing, astrodynamics, estimation theory, control, and space systems. Researchers intend to further develop existing technologies related to self-deployable construction tools, decentralized autonomy, attaching new components to existing structures while in orbit, and intelligent and interactive inspection.

"Our vision for basic and applied research will open a new frontier of opportunities to maximize the utility for satellites and other in-orbit assets by prolonging, enhancing or augmenting their mission capabilities," Choset said. "This ushers in a new era of satellite capabilities and configurations that will transform the future of space operations."

AFRL and AFOSR selected the CMU-led consortium's proposal, "Breaking the 'Launch Once, Use Once' Paradigm," as part of the newly established Space University Research Initiative (SURI). The University of Buffalo will lead a team from Penn State, Georgia Tech, MIT and Purdue in a second SURI proposal focused on tracking and gathering information on objects in space. Each proposal is eligible for up to $1 million in funding per year for three to five years.