Description: High Energy Laser for Construction & Welding, or HELCoW is a direct diode laser (DDL) subsystem capable of cleaning and conduction welding aluminum and stainless steel in orbital and lunar surface environments. HELCoW will be designed to be compatible as a payload on several Commercial Lunar Payload Services (CLPS) provider spacecraft, as well as orbital spacecraft, and shall be capable of operating in microtorr vacuum levels at lunar south pole daytime temperatures (-50 °C to 60°C). The proposed architecture allows the system to operate without consumables or maintenance for extended periods of time in the space environment while monitoring and adapting to system health. Funding will be used to advance the designs of the Laser Toolhead Subsystem, Robotic Positioning & Manipulation Subsystem, and the Lander Mounted (Control Electronics & Thermal Management) Subsystem to allow for system testing in thermal vacuum chamber environments and space environments on an orbital or lunar surface mission. Target markets include private space companies and several NASA programs.

Benefits: HELCoW technology applies to several portions of the STMD Strategic Framework, including Explore (Develop technologies supporting emerging space industries, including Satellite Servicing & Assembly, In Space/Surface Manufacturing, and Small Spacecraft Technologies) and Live (Develop exploration technologies and enable a vibrant space economy with supporting utilities and commodities). In-space, on-orbit, in-situ construction and assembly capabilities enable a vibrant space economy by de-constraining the spacecraft designers and mission planners to structures and systems that can both fit within and survive the environment of a launch vehicle fairing. HELCoW could eventually be used to assemble new spacecraft in orbit, repair or service spacecraft currently in orbit, assemble and repair pilot plants and robotic systems on the lunar surface, and recycle/reuse non-operational or retired spacecraft hardware. HELCoW has several applications that are relevant to private space companies. On-demand construction capabilities can reduce total system cost while improving system performance - space systems that are designed to be assembled in situ as opposed to launch can be larger in volume, be designed with fewer deployment mechanisms, and can employ less structural mass due to the absence of a requirement to survive launch environments. Material could be provided from recycled spacecraft, lunar-derived metals, or launched "spacecraft kits". HELCoW delivers these economic benefits by providing cleaning and welding services with a highly simplified laser system architecture, with built-in process monitoring to produce high quality, high reliability welds. The proposed prototype subsystem is designed with system longevity in mind and would require no servicing/consumables. HELCoW does not rely on very low TRL components or processes and could be delivered to the market within five years.