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Draft:Manufacturing of the International Space Station

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The Space Station Processing Facility at Kennedy Space Center - the prime factory for final fabrication and processing of station components for launch

The project to create the International Space Station required the utilization and/or construction of new and existing manufacturing facilities around the world, mostly in the United States and Europe. The agencies overseeing the manufacturing involved NASA, Roscosmos, the European Space Agency, JAXA, and the Canadian Space Agency. Hundreds of contractors[1] working for the five space agencies were assigned the task of fabricating the modules, trusses, experiments and other hardware elements for the station, and launching them individually in modular segments for the in-orbit assembly.

The fact that the project involved the co-operation of fifteen countries working together created engineering challenges that had to be overcome: most notably the differences in language, culture and politics, but also engineering processes, management, measuring standards and communication; to ensure that all elements connect together and function according to plan. The ISS agreement program also called for the station components to be made highly durable and versatile - as it is intended to be used by astronauts indefinitely. A series of new engineering and manufacturing processes and equipment were developed, and shipments of steel, aluminum and other materials were needed for the construction of the space station components.[2]

Factories

List of manufacturing facilities used in the construction and fabrication of the International Space Station modular components:

All modules and sections are transported to these buildings except the Russian modules Zarya, Zvezda, Pirs and Poisk.

Manufacturing Information and Processes

A variety of manufacturing processes were used for each of the components of the space station.

Space Station element Overseeing agency and contractor Manufacturing
facility
Materials
used
Manufacturing date Mass
(kg)
Manufacturing Processes Isolated View
Zarya (FGB)[3] Roscosmos Khrunichev State Research and Production Space Center 1994 19,323
Unity (Node 1),[4] PMA-1 & PMA-2 NASA Marshall Space Flight Center June 6, 1997 11,612
Zvezda (Service Module)[5] Roscosmos Khrunichev State Research and Production Space Center 1985 19,051
Z1 Truss & PMA-3 NASA Michoud Assembly Facility 1999 8,755 (Z1)
P6 Truss & Solar Arrays NASA Michoud Assembly Facility

Truss

Solar Arrays

1999/2000 15,824

Destiny (US Laboratory)[6] NASA Marshall Space Flight Center December 12, 1997 14,515
External Stowage Platform-1 NASA
  • Airbus DS Space Systems
Goddard Space Flight Center[7] Steel 2000 5,760
Canadarm2 (SSRMS) Canadian Space Agency MDA Space Missions, Brampton Ontario Titanium 2000/01 4,899
  • Seamless rolling
  • Milling
  • Robotic assembly

Quest (Joint Airlock)[8] NASA Marshall Space Flight Center 2000 6,064
Pirs (Docking Compartment & Airlock) RKK Energia Korolyov, Moscow Oblast 1998 3,580
S0 Truss[9] NASA Michoud Assembly Facility 13.4 13,970
Mobile Base System NASA Northrop Grumman factory in Carpinteria, CA 2001 1,450
S1 Truss and Radiators NASA Michoud Assembly Facility November 21, 2006 14,120
P1 Truss and Radiators NASA Michoud Assembly Facility 2005/06 13.748 same as S1 Truss
ESP-2 NASA
  • Airbus DS Space Systems
Goddard Space Flight Center October 2005 2,676
P3/P4 Truss & Solar Arrays[10] NASA Michoud Assembly Facility

Truss

Solar Arrays

2005/06 15,900

P5 Truss[11] NASA Operations and Checkout Building Anodized steel February 2007 1,818
S3/S4 Truss & Solar Arrays NASA Michoud Assembly Facility Same as P3/P4 trusses May 12, 2005 15,900 Same as P3/P4 trusses
S5 Truss and ESP-3 NASA Operations and Checkout Building Steel (some anodized) 2007 13.795 Same as P5 and ESP-1 and 2
Harmony (Node 2)
Relocation of P6 Truss
European Space Agency, Italian Space Agency Thales Alenia Space factory in Cannes, France Stainless steel May 2003 14,288
Columbus (European Laboratory)[12] European Space Agency European Space Research and Technology Centre Stainless steel April 2006 12,800
Dextre (SPDM)
Japanese Logistics Module (ELM-PS)
1J/A 2008-03-11 Space Shuttle Endeavour (STS-123) 4.4 (ELM-PS) 4,200 (ELM-PS)
Japanese Pressurized Module (JEM-PM)
JEM Robotic Arm (JEM-RMS)[13][14]
JAXA (formerly NASDA) Tanegashima Space Center November 2005 15,900 (JEM-PM)

S6 Truss & Solar Arrays 15A 2009-03-15 Space Shuttle Discovery (STS-119) 73.2 15,900
Japanese Exposed Facility (JEM-EF) 2J/A 2009-07-15 Space Shuttle Endeavour (STS-127) 4,100
Poisk (MRM-2)[15][16] 5R 2009-11-10 Soyuz-U
(Progress M-MIM2)
3,670
ExPRESS Logistics Carriers 1 & 2 NASA All three facilities
Cupola &
Tranquility (Node 3)
20A 2010-02-08 Space Shuttle Endeavour (STS-130) 6.5 (Node 3)
1.5 (Cupola)
  • 4.25 (Node 3)
    2.95 (Cupola)
12,247 (Node 3)
1,800 (Cupola)
Rassvet (MRM-1)[17] Roscosmos, NASA Khrunichev State Research and Production Space Center 5,075
Leonardo (PMM) and EXPRESS Logistics Carrier 4 ULF5 2011-02-24 Space Shuttle Discovery (STS-133) 6.6 9,896 (Leonardo) 31

Alpha Magnetic Spectrometer, OBSS and EXPRESS Logistics Carrier 3 ULF6 2011-05-16 Space Shuttle Endeavour (STS-134) 6,731 (AMS-02)

Bigelow Expandable Activity Module[18] 2016-04-08 Falcon 9

(SpaceX CRS-8)

4 3.2 16
NanoRacks Airlock Module 2019-10-15[19][20] Falcon 9

(SpaceX CRS-19)[21]

Nauka (MLM)
European Robotic Arm[22]
3R 2020[23] Proton-M 20,300 (Nauka) 70
Prichal 2022 (TBD)[24] Soyuz 2.1b

(Progress M-UM)

4,000
NEM-1 (SPM-1) 2022 (TBD)[24] Proton-M
Space Station element Overseeing agency and contractor Manufacturing
facility
Materials
used
Manufacturing date Mass
(kg)
Manufacturing Processes Isolated View

Transportation

Once manufactured or fabricated sufficiently, most of the space station elements were transported by aircraft (usually the Airbus Beluga or the Aero Spacelines Super Guppy) to the Kennedy Space Center Space Station Processing Facility for final manufacturing stages, checks and launch processing.

References

  1. ^ https://www.esa.int/Our_Activities/Human_and_Robotic_Exploration/International_Space_Station/Companies_involved_with_ISS
  2. ^ https://www.nasa.gov/mission_pages/station/structure/elements/integrated-truss-structure
  3. ^ Wade, Mark (15 July 2008). "ISS Zarya". Encyclopaedia Astronautica. Archived from the original on 27 February 2009. Retrieved 2009-03-11. {{cite web}}: Unknown parameter |deadurl= ignored (|url-status= suggested) (help)
  4. ^ "Unity Connecting Module: Cornerstone for a Home in Orbit" (PDF). NASA. January 1999. Archived from the original (PDF) on 17 March 2009. Retrieved 2009-03-11. {{cite web}}: Unknown parameter |deadurl= ignored (|url-status= suggested) (help)
  5. ^ "Zvezda Service Module". NASA. 11 March 2009. Archived from the original on 23 March 2009. Retrieved 2009-03-11. {{cite web}}: Unknown parameter |deadurl= ignored (|url-status= suggested) (help)
  6. ^ "US Destiny Laboratory". NASA. 26 March 2007. Archived from the original on 9 July 2007. Retrieved 2007-06-26. {{cite web}}: Unknown parameter |deadurl= ignored (|url-status= suggested) (help)
  7. ^ https://www.nasa.gov/centers/goddard/images/content/402222main_Techs_working_on_ELC_1019.jpg
  8. ^ "Space Station Extravehicular Activity". NASA. 4 April 2004. Archived from the original on 3 April 2009. Retrieved 2009-03-11. {{cite web}}: Unknown parameter |deadurl= ignored (|url-status= suggested) (help)
  9. ^ "Space Station Assembly: Integrated Truss Structure". NASA. Archived from the original on 7 December 2007. Retrieved 2007-12-02. {{cite web}}: Unknown parameter |deadurl= ignored (|url-status= suggested) (help)
  10. ^ "P3 and P4 to expand station capabilities, providing a third and fourth solar array" (pdf). Boeing. July 2006. Retrieved 2007-12-02.
  11. ^ "STS-118 MISSION OVERVIEW: BUILD THE STATION…BUILD THE FUTURE" (PDF). NASA PAO. July 2007. Archived from the original (PDF) on 1 December 2007. Retrieved 2007-12-02. {{cite web}}: Unknown parameter |deadurl= ignored (|url-status= suggested) (help)
  12. ^ "Columbus laboratory". ESA. 10 January 2009. Archived from the original on 30 March 2009. Retrieved 2009-03-06. {{cite web}}: Unknown parameter |deadurl= ignored (|url-status= suggested) (help)
  13. ^ "About Kibo". JAXA. 25 September 2008. Archived from the original on 10 March 2009. Retrieved 2009-03-06. {{cite web}}: Unknown parameter |deadurl= ignored (|url-status= suggested) (help)
  14. ^ "Kibo Japanese Experiment Module". NASA. 23 November 2007. Archived from the original on 23 October 2008. Retrieved 2008-11-22. {{cite web}}: Unknown parameter |deadurl= ignored (|url-status= suggested) (help)
  15. ^ Zak, Anatoly. "Docking Compartment-1 and 2". RussianSpaceWeb.com. Archived from the original on 10 February 2009. Retrieved 26 March 2009. {{cite web}}: Unknown parameter |deadurl= ignored (|url-status= suggested) (help)
  16. ^ Bergin, Chris (9 November 2009). "Russian module launches via Soyuz for Thursday ISS docking". NASASpaceflight.com. Archived from the original on 13 November 2009. Retrieved 10 November 2009. {{cite web}}: Unknown parameter |deadurl= ignored (|url-status= suggested) (help)
  17. ^ "NASA Extends Contract With Russia's Federal Space Agency" (Press release). NASA. 9 April 2007. Archived from the original on 23 June 2007. Retrieved 2007-06-15. {{cite press release}}: Unknown parameter |deadurl= ignored (|url-status= suggested) (help)
  18. ^ "NASA to Test Bigelow Expandable Module on Space Station". NASA. 16 January 2013. Retrieved 16 January 2013.
  19. ^ Frommert, Hartmut (8 December 2018). "International Space Station Flight Schedule". Retrieved 10 December 2018.
  20. ^ Pietrobon, Steven (19 January 2019). "United States Commercial ELV Launch Manifest". Retrieved 19 January 2019.
  21. ^ http://nanoracks.com/nanoracks-adds-thales-alenia-space-to-airlock/
  22. ^ "FGB-based Multipurpose Lab Module (MLM)". Khrunichev State Research and Production Space Centre. Archived from the original on 27 September 2007. Retrieved 2008-10-31.
  23. ^ Pietrobon, Steven (8 February 2019). "Russian Launch Manifest". Retrieved 8 February 2019.
  24. ^ a b "Рогозин — РБК: "Формула "космос вне политики" не работает"" [Rogozin to RBC: The "cosmos out of politics" formula does not work]. RBC.ru (in Russian). 10 January 2019. Retrieved 12 January 2019.