STARFAB: Concept of Operations and Preliminary Design of an Orbital Automated Hub for in Space Operation and Service Activities

Currently constrained by short operational lifetimes and minimal on-orbit support infrastructure, service satellites hold significant potential for future commercial and sustainable space services. To support these in-situ services, this paper introduces STARFAB as an innovative concept for an automated orbital hub and warehouse units. The primary goal of STARFAB is to provide essential infrastructure for On-Orbit Servicing and In-Space Assembly and Manufacturing operations. It aims to enable the storage, maintenance, inspection, refuelling, testing, recycling, assembly, and manufacturing of spacecraft components directly in orbit. STARFAB's architecture consists of a modular space station with a central linear structure. Modular secondary units dedicated to specific functions, such as storage, refuelling, or manufacturing, are attached to this primary structure. A large external robotic arm assists in handling spacecraft, secondary units, and payloads. Smaller internal robotic manipulators perform tasks within the station, while a rail-based shuttle system transports payloads and robotic agents. Key technologies include standardized robotic interfaces (HOTDOCK) for modular assembly and reconfiguration, a dedicated robotic module (MIM) for automated inspection and maintenance, and standardized modules for the storage of components and payloads, facilitating efficient robotic manipulation. Application scenarios range from short-term missions, such as orbital replacement units and fuel resupply, to long term operations involving the assembly of telescope mirrors, additive manufacturing of large structures, and debris collection. In conclusion, STARFAB offers a promising infrastructure solution for the sustainable development of the space sector, providing robotic, in-orbit capabilities for storage, maintenance, and reuse of space resources. Future work will focus on refining the warehouse function design and developing a terrestrial demonstrator. This project is co-funded by the European Union in the framework of the HORIZON EUROPE Research Programme "Future Space Ecosystem and Enabling Technologies" (Project No. 101135507) entitled "A Space Warehouse Concept and Ecosystem to Energize European ISAM (STARFAB)".