Rosotics Aims to Construct Large-Scale Space Shipyards through 3D Printing Technology

Located in Mesa, Arizona, Rosotics has maintained a rather discreet presence. A quick glance at their website might leave you with the impression that their primary focus revolves around the development and sale of sizable metal 3D printers, particularly to clients in the aerospace and defense sectors.

However, over the last three years, the company has been silently crafting ambitious plans that involve the deployment of large-scale spacecraft. These spacecrafts are intended to carry multiple smaller ones, aiming to create 3D-printed shipyards and fuel depots in the low Earth orbit (LEO). The vision that Rosotics harbors is one of a future where space infrastructure is constructed in orbit, not merely launched from Earth.

“Halo represents the zenith of several years of thorough research and development, a project we’ve managed to keep under wraps for quite some time,” shared Christian LaRosa, CEO of Rosotics, during a recent dialogue. “Halo’s purpose is to fabricate what we term as carrier vessels. These are essentially our frontline strategy for manufacturing directly in orbit.”

The venture is in the process of developing what it calls ‘motherships’, large carrier vehicles that will span five meters in diameter. These motherships are designed to transport over a dozen smaller, self-governing spacecraft known as R2. These will be responsible for assembling substantial aluminum ‘stations’, potentially serving as fuel depots, shipyards, or even power generation stations.

LaRosa repeatedly highlighted the importance of secrecy: “On a global scale, merely three or four individuals were privy to the full scale of our ambitions, and we’ve devoted considerable time consulting, developing, and testing to reach our current position.” With Halo now entering the commercial zone and beginning to generate revenue, LaRosa believes the time is ripe to unveil these ambitious projects.

LaRosa elaborates on a novel and highly efficient methodology the firm has developed for 3D printing in the challenging conditions of space, a task that proves significantly more complex than its terrestrial counterpart. This technique utilizes induction through a printer named Reaper and a method known as “cold welding.” This process allows metals to bond at minimal to no heat.

Cold welding, a phenomenon previously observed in space to the detriment of certain missions, happens when two metal surfaces merge without an oxide layer separating them. While terrestrial conditions naturally produce these oxides, Rosotics ingeniously leverages this chemical interaction for larger-scale applications.

“We regard cold welding as a pivotal breakthrough for enabling on-orbit services such as servicing, assembling, and manufacturing, as well as the creation of substantial infrastructure in space,” stated LaRosa.

LaRosa envisions the R2 units working in a collective manner to construct orbital structures, with periodic returns to the mothership for more aluminum resources. He suggests that these materials could be replenished not only through third-party launches but also other means, serving additional functions such as orbit elevation or stabilization of the completed stations.

According to LaRosa, each aluminum structure will be substantial, comparable or even surpassing the size of the ISS. He anticipates that the company will commence production of an integrated spacecraft within 12 to 18 months, facilitated by a new production facility set to be established in Boulder, Colorado. A launch into space could occur within the next 2 to 3 years.

The financial implications of such endeavors are significant, but LaRosa attributes the company’s capacity to advance on a relatively modest budget of $2.6 million, obtained from Tim Draper among others, to the strategic location of Mesa and its distance from pricier aerospace centers. Moreover, Rosotics plans to generate funds through the sales of the Halo printers, drawing a parallel with how SpaceX financed its massive Starship rocket through the revenue from its Starlink satellite internet service.

“Achieving this was beyond the realm of mere investment; it necessitated financial stability and consistent revenue. Halo will, indirectly, finance the station and the methodologies we adopt for its construction,” LaRosa concluded.