On-orbit assembly technology: A review

Large-scale space platforms cannot be deployed through a single launch, owing to the inherent constraints of launch vehicle payload capacity, fairing envelope dimensions, and structural complexity. On-orbit assembly offers a compelling solution to this challenge by virtue of its intrinsic capability to circumvent these limitations. This paper presents a systematic analysis of recent research advances across four critical domains: on-orbit assembly processes, robotic technologies for on-orbit assembly, simulation methodologies, and representative engineering applications. The analysis further identifies several prevailing technical bottlenecks, including insufficient assembly precision, inadequate stiffness and stability of space-based robotic systems, dynamic deformation induced by large flexible structures, and limited fidelity of ground-based simulation environments. In response, prospective development trends are proposed, encompassing high-precision intelligent assembly strategies, innovations in robot materials and structural design, enhanced dynamic control of large flexible structures, and iterative advancements in ground simulation technologies. The findings presented herein are intended to offer substantive theoretical guidance and practical reference for the on-orbit assembly of large-scale space structures and the sustained advancement of deep-space exploration initiatives.