How Kurs Orbital Builds a Next-Generation Module for Autonomous Docking in Space

Kurs Orbital develops the ARCap autonomous docking module to extend satellite life, service space stations, and remove space debris. With Xometry's prototyping services, the team accelerates sensor prototype validation, aiming for a flight-ready module by the end of 2025.

Industry
Aerospace
Country
flag

Italy

Use case
R&D
Technology
3D PrintingCNC Machining
Product

ARCap module

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Kurs Orbital, an innovative Italian startup, expands human activities beyond Earth by providing advanced docking technology for satellite life extension, space station servicing, and space debris removal missions.

At Kurs Orbital, our mission is to make the space sector more sustainable. As space engineers and enthusiasts, we have leveraged our experience to develop the “ARCap” module. This is our cutting-edge patented technology that addresses the growing issue of space sustainability by allowing satellites and spacecraft to perform autonomous rendezvous and docking maneuvers without human intervention. Until now, only major space agencies had the resources and technology to achieve this. We are working hard to make this capability accessible and commercially viable for everyone, so that over time, our ARCap module can be integrated into any space vehicle. In short, we are opening up new horizons for the entire aerospace industry.

Table of Contents

  • The Inspiration Behind ARCap: Space Sustainability
  • The Advanced Sensor Suite: The Heart of ARCap Innovation
  • Shaping the Future of Space Operations

The Inspiration Behind ARCap: Space Sustainability

Our journey started with the pressing need to make space operations more sustainable. Satellites, which cost between $150 and $500 million, are often unrecoverable once they fail in orbit. With the impending decommissioning of the International Space Station (ISS) in 2030, there is a pressing need for new solutions. This is where our ARCap module comes into play, reducing space debris and contributing to a more sustainable future for space exploration.

Conceptualizing the ARCap was not an easy task. Based on the extensive experience of the Kurs system, which has been operating since 1985 with over 300 successful dockings to the ISS, we knew we had a solid foundation on which we could build a more advanced module. The new ARCap module features three types of sensors, can handle uncooperative targets, and is a single standardized module that can easily be installed on any spacecraft. One of our main challenges has been time, as our goal is to have a prototype ready by the end of 2025.

ARCap module demonstrating autonomous docking with another spacecraft in orbit.
Kurs Orbital’s ARCap module performing an autonomous docking maneuver in space © Kurs Orbital

The Advanced Sensor Suite: The Heart of ARCap Innovation

The advanced sensor suite of ARCap allows for precise navigation and docking without human intervention. The ARCap module includes three distinct types of sensors, each of which plays a crucial role in ensuring the success of docking operations. Radar takes center stage during the initial phases of approach, measuring the distance to the target and guiding the spacecraft in its approach. The laser rangefinder and machine vision take over at shorter distances, taking care of the final rendezvous phase and docking/capture operations thanks to their high precision. Behind the scenes, patented algorithms leverage decades of team experience in developing the Kurs system, ensuring smooth and reliable in-orbit maneuvers.

This system integrates seamlessly into various spacecraft, ensuring a wide range of applications. The ability to handle uncooperative targets makes it a revolutionary system, which can help refuel future commercial space stations and remove space debris. ARCap mitigates the costly and wasteful practice of discarding satellites and offers practical solutions for refueling space stations in the post-ISS era.

We are currently creating prototypes of individual sensors that will be evaluated in conditions simulating in-orbit operations in the fall of 2024. These ground tests are essential for validating the performance and functionality of the sensors. After the success of the ground tests, the sensors will be integrated into a single prototype, the first integrated ARCap module. This phase involves ensuring seamless communication and coordination between the different sensors. The ultimate goal is to produce the first flight-ready ARCap module by the end of 2025.

Spacecraft module diagram with key components labeled.
Diagram of a spacecraft module showing the ARCap module © Kurs Orbital

Shaping the Future of Space Operations

We are thrilled to be part of an ASI (Italian Space Agency) project together with Argotec, the Polytechnic of Turin, and the University of Pisa. We have some ongoing discussions for both projects and collaborations that we hope to announce soon. It is an honor to see the great interest our technology and our vision for a more sustainable space is generating, both among major industry players and smaller ones.

For us, the development process of ARCap has been incredibly rewarding. Seeing our technology evolve from an idea to a prototype is a testament to the dedication and expertise of our team. We are very excited to expand our team and continue testing and refining our system. Our vision is for ARCap to play a key role in making space exploration more sustainable and efficient.

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