WBI’s Manufacturing Readiness Assessment (MRA) Advances Space Propulsion through Collaborative Partnerships
Conducting a comprehensive MRA as part of this process ensures that the technology is ready to meet the challenges of tomorrow, delivering reliable and effective solutions for national defense.
The Air Force Research Laboratory (AFRL) Materials and Manufacturing Directorate called on Wright Brothers Institute to produce a Space Propulsion Market Analysis Study, marking a pivotal step forward in the advancement of space propulsion technology. The study initiated a Manufacturing Readiness Assessment (MRA) on Liquid Electrospray technology, uncovering the current state of the art in TILE (Thrust-Induced Light Electrospray) capabilities.
TILE Capabilities & a Strategic Advantage
TILE technology is of strategic importance to the Air Force for several reasons, particularly in enhancing the performance and operational flexibility of space assets. As space becomes an increasingly contested domain, the ability to maneuver satellites and other space-based systems with precision and efficiency is paramount. TILE thrusters, which are compact, lightweight, and capable of delivering fine-tuned thrust, offer the Air Force the capability to adjust satellite orbits, maintain positions, and avoid collisions or potential threats. Improved performance and extended mission duration are crucial for success. In contested environments, where re-supply and replacement may not be feasible, the extended durability of TILE systems provides a strategic advantage.
Understanding the Manufacturing Readiness Assessment (MRA) Process
A Manufacturing Readiness Assessment (MRA) is a crucial step in evaluating and improving the manufacturing processes for new technologies. Traditional MRAs are designed to assess the maturity of a manufacturing process, identify risks, and recommend actions to mitigate those risks before full-scale production begins. This ensures that a technology can be reliably produced at the required quality and quantity levels.
The benefits of conducting an MRA are substantial. It provides a clear understanding of the manufacturing process's current state, identifies potential bottlenecks, and highlights areas for improvement. By addressing these issues early, companies can avoid costly production delays, reduce waste, and improve the overall quality of the final product. For the Air Force, this means having access to reliable, high-performance TILE thrusters that meet mission requirements and support national security objectives.
Manufacturing that Ready to Move
While conducting the MRA, Revolution Space, a Massachusetts-based TILE manufacturer, stood out in the market due to its advanced production capabilities. While many other efforts in TILE technology were still in the research phase, Revolution Space had moved beyond this stage, securing venture funding, developing a comprehensive roadmap, and identifying key Space Force customers. This focus on rapid market entry and manufacturing capability enhancement set the stage for the Space Propulsion Market Analysis Study to zero in on Revolution Space's manufacturing process.
The Collaborative Benefits of WBI's Partnership with FASTLANE
The collaboration between Wright Brothers Institute (WBI) and FASTLANE was integral to the success of this project, showcasing the strength of WBI’s future-focused ecosystem. The MRA revealed critical areas for improvement in Revolution Space's TILE manufacturing process. To address these shortfalls and enhance the overall production process, WBI brought in FASTLANE, the local Manufacturing Extension Partnership (MEP) for Dayton. This collaboration aimed to advance this transformational technology in the U.S. market by significantly increasing both production capacity and the operational lifetime of individual TILE systems.
In March 2023, Revolution Space was producing around 10 TILEs per month, with each TILE thruster operating for less than three days—far short of the 11-day operational lifetime threshold required for a viable business case. The collaboration with WBI and FASTLANE led to a breakthrough: the identification of a manufacturer capable of producing frames that resolved the "leakage" problem that had previously limited TILE thruster operation.
As a result, the operational lifetime of TILE thrusters increased dramatically, from under three days to over 22 days—more than double the required threshold.
The collaborative benefits of this partnership extended beyond just solving immediate technical problems. WBI and FASTLANE were able to integrate their efforts into a broader strategy that aligned with the Air Force’s long-term goals. By working together, they were able to:
Accelerate Time-to-Market: The combined expertise of WBI and FASTLANE helped Revolution Space quickly overcome manufacturing challenges, accelerating the timeline for bringing TILE technology to market.
Enhance Production Capacity: Through the MRA, WBI and FASTLANE identified key improvements that allowed Revolution Space to scale up production from 10 TILEs per month to over 200 per month, with a clear path to reaching 1,000 per month by 2025.
Improve Quality and Reliability: FASTLANE’s manufacturing expertise ensured that the improvements made to the TILE production process not only increased output but also enhanced the quality and reliability of the final product, leading to extended operational lifetimes for TILE thrusters.
Support National Defense Objectives: By aligning their efforts with the needs of the Air Force, WBI and FASTLANE helped ensure that TILE technology would meet the strategic requirements of the U.S. military, providing a critical edge in space operations.
TILE Technology Rapidly Advancing
Today, TILE production capacity exceeds 200 chips per month, supporting system testing at Edwards Air Force Base with other AFRL organizations in preparation for on-orbit testing scheduled for late 2024. Moreover, TILEs have now demonstrated lifetime performance at constant thrust for over 22 days.
Thanks to Revolution Space's successful collaboration with the Materials and Manufacturing Directorate and WBI, there is now a clear path to achieving the PALOMINO Generation 1 production goal of 1,000 TILEs per month, with operational lifetimes exceeding 30 days by 2025. This represents a significant leap forward in space propulsion technology, bringing us closer to realizing the potential of TILE systems in supporting the next generation of space missions.