The Defense Advanced Research Projects Agency (DARPA) has initiated the Novel Orbital and Moon Manufacturing, Materials, and Mass-efficient Design (NOM4D) program in 2022, aimed at developing manufacturing methods directly in space. This ambitious project involves sending raw materials into orbit to assemble complex structures, reducing dependence on terrestrial supply chains and strengthening the USA’s strategic position in space. Collaborations with prestigious institutions such as the California Institute of Technology (Caltech) and the University of Illinois at Urbana-Champaign are underway to test these technologies in orbit as early as 2026.
NOM4D: a revolution in space manufacturing
DARPA’s Novel Orbital and Moon Manufacturing, Materials, and Mass-efficient Design (NOM4D) program, launched in 2022, aims to transform the way space structures are designed and built. Traditionally, components destined for space are manufactured on Earth and then launched into orbit, a method that is costly and limited by launch constraints. NOM4D proposes an innovative approach: sending raw materials into orbit and assembling complex structures there. This method would overcome current limitations linked to the volume and mass of payloads, paving the way for the construction of previously unimaginable space superstructures. By focusing on in-situ manufacturing, the program aims to reduce costs and increase the efficiency of space missions, while strengthening U.S. strategic autonomy in space.
Strategic collaborations for in-orbit testing
To make NOM4D’s ambitious goals a reality, DARPA has teamed up with leading institutions, including the California Institute of Technology (Caltech) and the University of Illinois at Urbana-Champaign. These partnerships aim to develop and test space manufacturing technologies directly in orbit. Among the flagship projects is a collaboration with space manufacturing start-up Momentus, which plans to test a Caltech-designed composite spar assembly robot as early as 2026. This robot will be tasked with building an antenna component in orbit, demonstrating the feasibility of assembling complex structures in space. This crucial step will validate the technologies needed to build large-scale space infrastructures, reducing dependence on launches from Earth and opening up new prospects for space exploration and exploitation.
Strategic implications for U.S. defense
The NOM4D program is not just about technological advances; it is also of major strategic importance for US defense. The ability to manufacture and assemble structures directly in orbit offers a significant advantage in terms of flexibility and rapid deployment of military space infrastructures. In a context where space is becoming a potential theater of operations, having the ability to build satellites, stations or observation platforms in orbit would enable U.S. armed forces to maintain strategic superiority. In addition, this autonomy would reduce vulnerability linked to terrestrial supply chains and the logistical constraints of launches, strengthening the resilience of defense space capabilities in the face of potential adversaries.
Towards a new space economy
Beyond the military aspects, orbital manufacturing could transform the space economy. The possibility of building large structures directly in space opens up unprecedented prospects for projects such as space solar power plants, habitats for human exploration or next-generation telescopes. This approach could also stimulate the private sector, reducing the costs and risks associated with multiple launches and enabling the development of new space industries. According to projections, the global space market, valued at over $400 billion in 2022, could reach nearly $1,000 billion by 2040, driven by innovations such as those proposed by the NOM4D program.
Technical challenges and future prospects
Implementing orbital manufacturing involves considerable technical challenges. These include developing materials suited to space conditions, designing robots capable of operating autonomously in microgravity, and managing the supply of raw materials. Nevertheless, recent advances in robotic technologies, composite materials and autonomous systems offer promising solutions. The tests scheduled for 2026 will be a decisive step in assessing the feasibility of these technologies in real-life conditions. If these tests are successful, they could usher in a new era of space engineering, in which Earth would no longer be the sole manufacturing site for extraterrestrial missions.
Impact on international competitiveness
In a context of heightened space competition, with nations like China investing massively in their space programs, the NOM4D program positions the United States at the forefront of technological innovation. Mastery of orbital manufacturing could confer a decisive competitive advantage, both militarily and commercially. By developing these capabilities, the United States is strengthening its leadership in space, ensuring a dominant presence in the exploitation and exploration of space, and setting standards for future international space activities.
DARPA’s NOM4D program represents a major breakthrough in the way humanity envisions the construction and operation of space infrastructure. By enabling direct manufacturing in orbit, it opens up unprecedented prospects for space defense, economics and exploration.
War Wings Daily is an independant magazine.