In-Space Inductive Foundry: Recycling, Sorting and Casting

Yolo Robotics LLC proposes developing the core technology for an inductive foundry to recycle, sort, and free-cast metals in space. The system consists of electromagnetic arrays that are independently commutated to induce heat and forces to melt and manipulate metals. This technology applies well-understood phenomena in a completely novel way for a substantial technological advance. Its compact, integrated hardware has no moving parts, an infinite workspace, and scales to match material throughput to available power. Current state of the art recycling and manufacturing is precise but slow, static, and life limited. The inductive foundry produces basic feedstocks (ingots, bars, plates, filament) and may ultimately produce complex shapes (brackets, tools, extrusions) significantly faster than additive or subtractive manufacturing. The rough products generated by our in-space inductive foundry can either be used in low-precision applications (radiators, scaffolding, tanks) or more complex applications using additional manufacturing processes in space. The inductive foundry is the ideal tool for remote and continuous in-space recycling and manufacturing. It has immediate applications on the ISS, a sustainable business case to manage orbital debris, and is a foundational element of the cislunar economy. In Phase I, Yolo Robotics concluded that this approach is feasible and successfully demonstrated moving, melting, forming, and cooling aluminum using its advanced inductive foundry technology. This Phase II effort shall integrate these processes into a complete prototype, culminating in a demonstration in vacuum on a reduced-gravity flight to validate the recycling process and characterize feedstocks produced in an analogous space environment. Yolo Robotics LLC proposes developing the core technology for an inductive foundry to recycle metals in space. Arrays of independently controlled induction coils create arbitrary eddy currents and Lorentz forces to suspend, melt, and reshape common aerospace metals. The core technology is capable of material processing (melting, solidifying, forming feedstock) as well as ancillary processes (sorting, purification, handling) and potentially more (annealing, welding, printing). The induction foundry can be programmed to produce basic feedstocks and simple parts significantly faster than additive or subtractive manufacturing. The compact, general-purpose hardware scales to match material throughput to available power. It is not limited by the size of work volume and there are no moving parts for a nearly infinite lifetime. This general-purpose tool has the potential to be the heart of all on orbit servicing, assembly, and manufacturing activities. Yolo Robotics will demonstrate an inductive foundry prototype in a reduced gravity, vacuum environment. First, the team shall develop a smart, integrated electromagnetic coil or “flux module”. These modules consist of a magnetic coil, backiron, resonant power amplifiers, local control systems, and global synchronization. Working in concert, numerous modules create programmable magnetic fields to perform all of the functions required for an inductive foundry. Module performance will be verified in independent and synchronized operation. Second, the team shall integrate numerous flux modules in a prototype inductive foundry for terrestrial, vacuum, and reduced gravity operation. This design will include design constraints (in the absence of gravity) required for operation on a small satellite or ISS ExPRESS rack. Application software will perform the functions: Movement Melting Flow control Forming Cooling These functions will be simulated in a magnetohydrodynamic (MHD) environment and validated in the real world. Validation will start in the lab, then move to high vacuum chambers to verify prototype performance, and culminate in a reduced gravity flight in vacuum to evaluate aluminum recycled in-analogous-space. Phase II deliverables: Material characterization reports Recycling performance report Photos and video documentation for outreach
Benefits: For NASA, the initial application of the induction foundry is to convert waste streams into useful feedstocks in support of remote and novel missions. At small scales, NASA can create a raw material reserve for repairs and new parts on the ISS and remote outposts. At larger scales, this technology can recycle orbital debris, convert rocket bodies, or even upcycle the ISS if otherwise deorbited. In the future, induction foundries will be a key element in cislunar and lunar infrastructure construction and operation. For non-NASA applications, inductive foundries enable new opportunities for the cislunar economy and beyond. Debris cleanup is feasible, selling fuel and feedstock. Microgravity manufacturing is a growing venture. And traditional aerospace can build large components on-orbit from scrap without deployment. Recycling enables grand endeavors like power satellites, hotels, and asteroid refinement.