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Scientists from the Institute of Materials and Machine Mechanics of the Slovak Academy of Sciences (SAS) have launched a new research project to develop robotic bolt-welding technology for use under vacuum conditions. The project, titled Robotic Simulator for Experimental Testing of Bolt Welding in Vacuum (ROBSIM – SPACE), has received nearly €1.5 million in funding from the Slovakia Programme. The goal is to verify, under laboratory conditions, a technological solution that could, in the future, enable autonomous satellite repairs and more efficient removal of space debris from orbit.

Within the ROBSIM – SPACE project, Slovak researchers are developing a robotic system capable of performing bolt welding in high-vacuum conditions for in-orbit applications. The core of the project is the construction of a robotic simulator to experimentally test and optimise the bolt-welding process on model surfaces representing space structures. The team aims to develop a scalable, large-volume vacuum chamber equipped with a robotic arm integrated directly into the working space. The system will also include a specially designed end effector, developed for terrestrial use but adapted for stable operation in a vacuum.

The research will focus on extreme vacuum welding of various structural materials, including applications through non-conductive layers such as protective coatings, insulation, and radiation-shielding materials. The quality of the welded joints will be verified through metallographic analyses and mechanical testing.

“The project builds on our existing capacitive bolt welding technology – a method that does not require adhesives or mechanical fasteners, is energy-efficient, and produces strong joints within a very short time. This new project elevates our ongoing cooperation with the European Space Agency (ESA) to a higher level,” says Naďa Beronská, Director of the Institute and project lead. “Our objective is to validate the system’s functionality in laboratory conditions and establish a technological foundation for its potential future use in orbital and lunar missions,” she adds.

Benefits for orbital safety and maintenance

“The technology under development has the potential to be applied in two key areas of space operations,” explains Marek Gebura from the Institute of Materials and Machine Mechanics of the SAS.

“The first is Active Debris Removal (ADR), where robotic arms could weld attachment points onto non-operational satellites, enabling their capture and safe deorbiting. The second is In-Space Assembly and Manufacturing (ISAM), which would allow the

assembly of large structures directly in orbit or the construction of infrastructure on the lunar surface without direct astronaut involvement.”

A particularly innovative aspect of the project is the ability to weld through non-conductive layers, such as satellite multi-layer insulation (MLI) blankets and protective coatings. These layers have so far represented a significant technological barrier to implementing such systems in on-orbit servicing missions.

The project will run from January 2026 to December 2028 and builds on the Institute’s previous experience in space research, including collaborations with prominent partners such as the Slovak company Space scAvengers, Germany’s Telespazio, Poland’s PIAP Space, and Ukraine’s Paton.

Prepared by: Jozef Bednár

Photo: ÚMMS SAS