Rosotics plans 3D printing of spaceship shipyards in orbit

Rosotics, based in Mesa, Arizona, has unveiled ambitious plans for 3D printing in space. After three years of development, the startup is presenting its “Halo” project, which envisages the production of orbital infrastructure directly in space.

The concept is based on large spacecraft, so-called “mother ships”, each of which houses over a dozen smaller autonomous spacecraft called R2. These R2 units will print massive aluminum structures in orbit that can serve as fuel depots, shipyards or even power generation facilities.

Christian LaRosa, CEO of Rosotics, explains: “Halo is the culmination of years of research and development for a long-term project that we have kept secret for a long time.” The motherships are to have a diameter of five meters and act as carriers for the R2 units.

For 3D printing in space, Rosotics uses a unique approach based on induction and a process known as “cold welding”. This involves joining metals with little or no heat – a phenomenon that occurs naturally in the vacuum of space.

The R2 units will produce swarm-like structures in orbit and periodically return to the mother ship to reload aluminum raw material. The finished structures will be comparable in size to the International Space Station or even larger.

Rosotics plans to begin production of an integrated spacecraft in 12 to 18 months. A new production facility in Boulder, Colorado, is planned for this purpose. The first space flight is expected in two to three years.

The ambitious project will be financed in part through the sale of Halo printers to customers in the aerospace and defense industries. LaRosa compares this strategy to SpaceX, which is using its Starlink satellites to fund the Starship project.