“We want to build big things in space. To build big things in space, you must start manufacturing things in space. This is an exciting new frontier,” said Miller.

The project – dubbed NOM4D, short for Novel Orbital and Moon Manufacturing, Materials, and Mass-efficient Design – seeks to transform how people think about space infrastructure development. Picture constructing massive structures in orbit, like a 100-meter solar array built using advanced laser technology.

“We’d love to see large-scale structures like satellite antennas, solar panels, space telescopes or even parts of space stations built directly in orbit. This would be a major step toward sustainable space operations and longer missions,” said team member Tianchen Wei, a third-year Ph.D. student in materials science and engineering.

UF received a $1.1 million DARPA contract to carry out this pioneering research over three phases. While other universities explore various aspects of space manufacturing, UF is the only one specifically focused on laser forming for space applications, Miller said.

A major challenge of the NOM4D project is overcoming the size and weight limitations of rocket cargo. To address these concerns, Miller’s team is developing laser-forming technology to trace precise patterns on metals to bend them into shape. If executed correctly, the heat from the laser bends the metal without human touch; a key step toward making orbital manufacturing a reality.

“With this technology, we can build structures in space far more efficiently than launching them fully assembled from Earth,” said team member Nathan Fripp, also a third-year Ph.D. student studying materials science and engineering. “This opens up a wide range of new possibilities for space exploration, satellite systems and even future habitats.”

Miller said laser bending is complex but getting the correct shape from the metal is only part of the equation.

“The challenge is ensuring that the material properties stay good or improve during the laser-forming process,” she said. “Can we ensure when we bend this sheet metal that bent regions still have really good properties and are strong and tough with the right flexibility?”

To analyze the materials, Miller’s students are running controlled tests on aluminum, ceramics and stainless steel, assessing how variables like laser input, heat and gravity affect how materials bend and behave.

“We run many controlled tests and collect detailed data on how different metals respond to laser energy: how much they bend, how much they heat up, how the heat affects them and more. We have also developed models to predict the temperature and the amount of bending based on the material properties and laser energy input,” said Wei. “We continuously learn from both modeling and experiments to deepen our understanding of the process.”

The research started in 2021 and has made significant progress, but the technology must be developed further before it’s ready for use in space. This is why collaboration with the NASA Marshall Space Center is so critical. It enables UF researchers to dramatically increase the technology readiness level (TRL) by testing laser forming in space-like conditions inside a thermal vacuum chamber provided by NASA. Fripp leads this testing using the chamber to observe how materials respond to the harsh environment of space.

“We've observed that many factors, such as laser parameters, material properties and atmospheric conditions, can significantly determine the final results. In space, conditions like extreme temperatures, microgravity and vacuums further change how materials behave. As a result, adapting our forming techniques to work reliably and consistently in space adds another layer of complexity,” Fripp said.

Another important step is building a feedback loop into the manufacturing process. A sensor would detect the bending angle in real time, allowing for feedback and recalibration of the laser’s path.

As the project enters its final year, finishing in June of 2026, questions remain – especially around maintaining material integrity during the laser-forming process. Still, Miller’s team remains optimistic. UF moves one step closer to a new era of construction with each simulation and laser test.

“It's great to be a part of a team pushing the boundaries of what's possible in manufacturing, not just on Earth, but beyond,” Wei concluded.