Attachment A4-Topic 4-Statement of Objectives.pdf

Attachment A4: Statement of Objectives (SOO) Topic 4 NextSTEP-3 Appendix A

1. PURPOSE

This Statement of Objectives (SOO) defines the mission need, objectives, desired outcomes and constraints to enable industry to propose commercially viable and credible solutions for advanced In-Space Manufacturing (ISM) technologies supporting future lunar, Martian, and deep-space exploration missions.

Offerors are expected to apply independent scientific and engineering judgment in selecting technical approaches and proposed solutions that best satisfy the objectives and outcomes defined herein

See Appendix A for additional solicitation details.

2. BACKGROUND/MISSION NEED

NASA’s strategic objective to extend sustained human presence beyond Earth orbit requires the ability to autonomously produce critical tools, replacement parts, and functional components during long-duration missions. In-space manufacturing capabilities reduce dependence on Earth-based resupply, increase mission adaptability and resiliency, and improve operational sustainability for future exploration architectures.

In-Space Manufacturing (ISM) technologies are being advanced to support future lunar surface operations, Mars missions, orbital platforms, and other deep-space applications. NASA seeks integrated manufacturing systems capable of reliably producing mission-relevant components in reduced gravity or microgravity environments while minimizing crew intervention and operational burden.

For the purposes of this effort, “mission-relevant” refers to manufactured components or subsystems whose functions directly enable NASA’s Moon-to Mars or Moon Base architectures by enabling operational capabilities in microgravity or reduced-gravity environments, supporting extraterrestrial surface or orbital infrastructure, and addressing identified in-space manufacturing shortfalls.

Current manufacturing technologies have demonstrated promising capability at lower technology readiness levels; however, substantial technical challenges remain in achieving reliable, autonomous, and repeatable manufacturing operations in reduced-gravity and microgravity environments. These challenges include feedstock management, process stability, quality assurance, anomaly detection, post-processing, and end-to-end workflow integration across diverse materials and manufacturing methods.

This effort is fundamentally a research and development initiative intended to mature integrated ISM capabilities from laboratory and subsystem demonstrations toward operationally relevant manufacturing systems suitable for future spaceflight applications. NASA anticipates leveraging the results of this effort to inform future exploration architectures, integrated manufacturing capabilities supporting orbital and/or extraterrestrial surface operations, and resilient operational concepts for long-duration human and robotic missions.

https://www.nasa.gov/wp-content/uploads/2025/12/2025-architecture-update-for-publication.pdf?emrc=6a7b18b76717c https://www.nasa.gov/wp-content/uploads/2026/04/moon-base-architecture-users-guide.pdf?emrc=6a7b18b766f5d

3. OBJECTIVES

The overall objective of this effort is to develop, integrate, and demonstrate advanced in-space manufacturing technologies capable of producing functional components in microgravity, reduced gravity, or extraterrestrial surface environments. Offerors shall select their target demonstration/operational environment. The solicitation is open to microgravity environments (e.g. International Space Station (ISS), Commercial Low Earth Orbit Destinations (CLDs), or hosted orbitals), reduced gravity environments (e.g. the lunar surface (≈0.16 g) or Martian surface (≈0.38 g)), or a combination of both, provided the design supports mission-relevant objectives. Offerors should tailor compliance to their proposed operational environment, meeting all expected safety and verification requirements appropriate to that environment. The effort shall focus on integrated manufacturing workflows, autonomous operational capability, quality assurance, and scalable manufacturing approaches suitable for future exploration missions.

Proposed approaches shall mature integrated technologies from a starting Technology Readiness Level (TRL) of 3-4 to a TRL of 5.

Successful efforts shall address the following key objectives:

3.1 Objective 1 - Develop and demonstrate an integrated manufacturing system capable of producing functional components using at least one feedstock selected from the following material classes: metals, polymers, composites, conductive inks, dielectric materials, lunar regolith, regolith simulants, and other ISRU-derived feedstocks. Offerors shall identify the selected feedstock(s), justify mission relevance and define the performance parameters to characterize and demonstrate the manufacturing capability. Demonstrations shall substantiate manufacturing accuracy, repeatability, yield, process stability, and other mission‑relevant performance parameters including, where applicable, dimensional motion accuracy, quality‑verification metrics, build time, post‑processing effectiveness, environmental compatibility, fault detection and recovery, and telemetry performance and other performance parameters in the relevant operational environment.

3.2 Objective 2 – Develop and demonstrate monitoring, inspection, and fault management capabilities capable of identifying, characterizing, and responding to manufacturing anomalies with minimal crew intervention. Proposed approaches shall support reliable and continuous manufacturing operations for future space-based applications.

3.3 Objective 3 – Engineer and demonstrate a complete manufacturing workflow from feedstock handling and deposition through post-processing, inspection, process monitoring, and anomaly recovery. Integrated workflows shall demonstrate reliable operation in reduced-gravity and microgravity-relevant environments while supporting compatibility with future orbital and surface platform integration.

3.4 Objective 4 – Demonstrate manufacturing processes capable of producing mission-relevant components with repeatable performance, dimensional accuracy, and operational consistency across representative manufacturing conditions. Demonstrations shall characterize process stability, yield, and quality metrics necessary for future operational implementation.

3.5 Objective 5 – Develop scalable ISM system architectures and operational concepts suitable for future long-duration exploration missions. Proposed systems shall address extensibility to future orbital, lunar, and Martian applications while minimizing operational complexity, crew workload, and logistics dependence.

4. PERFORMANCE OUTCOMES

The requirements contained in Attachment B4 establish the technical capabilities and performance objectives expected to be achieved during execution of the proposed effort.

Successful efforts shall achieve the following outcomes and associated performance objectives:

4.1 Demonstration of integrated feedstock manufacturing processes capable of producing functional components in reduced-gravity or microgravity-relevant environments. No material classes or manufacturing processes are designated as priority under this solicitation.

Offerors shall identify and justify the feedstock(s) that most effectively enable the production of mission‑relevant components. Proposed systems capable of processing multiple feedstocks within a single material class or multiple material classes are acceptable but not required.

4.2 Validation of manufacturing process stability, repeatability, and dimensional accuracy sufficient to demonstrate advancement toward operationally relevant ISM capability.

4.3 Demonstration of autonomous monitoring, inspection, anomaly detection, and fault recovery capabilities that reduce crew dependence and support continuous manufacturing operations.

4.4 Validation of integrated manufacturing workflows including feedstock handling, material deposition, post-processing, inspection, data logging, and anomaly recovery functions.

4.5 Characterization of manufacturing yield, process consistency, operational reliability, and environmental performance necessary to support future spaceflight implementation.

4.6 Delivery of technical data, operational insights, and manufacturing performance results supporting future NASA trade studies, mission architecture development, and operational planning for in-space manufacturing systems

5. CONSTRAINTS AND SCOPE

The following in-scope and out-of-scope constraints apply to all proposed technical approaches.

Offerors shall ensure their proposed technical approach strictly adheres to these boundaries.

5.1 In-Scope: The following elements shall be considered in scope and included in this effort:

5.1.1 Manufacturing Processes: Additive manufacturing processes supporting metals, polymers, composites, conductive inks, dielectric materials, lunar regolith, regolith simulants, or ISRU-derived feedstocks and related manufacturing approaches relevant to future space applications.

5.1.2 Autonomous Monitoring and Inspection: Potential for integrated process monitoring, inspection, anomaly detection, fault management, and telemetry collection capabilities supporting autonomous operations in a fully matured system. Level of autonomy must be compatible with selected demonstration environment.

5.1.3 Integrated Manufacturing Workflows: End-to-end manufacturing workflows including feedstock handling, material deposition, post-processing, inspection, process monitoring, and operational recovery functions.

5.1.4 Relevant Demonstrations: Testing and demonstrations in environments relevant to reduced gravity environments such as the lunar (≈0.16 g) or Martian (≈0.38 g) surface or microgravity operational conditions.

5.1.5 Operational Data Collection: Collection and reporting of manufacturing process data, operational telemetry, quality metrics, and performance characterization results supporting future NASA assessments.

5.2 Out-of-Scope: The following elements shall be considered out of scope and excluded from this effort:

5.2.1 Terrestrial Manufacturing Systems: Manufacturing systems or process demonstrations intended solely for terrestrial operations that do not provide relevance or applicability to orbital, extraterrestrial surface, or other space-based operational environments.

5.2.2 Crew-Dependent Inspection Operations: Approaches requiring continuous manual inspection or sustained crew intervention for nominal manufacturing operations.

5.2.3 Full Operational Flight Systems: Procurement or qualification of fully flight-certified operational manufacturing systems intended for deployment.

5.2.4 Non-Relevant Manufacturing Processes: Manufacturing technologies or applications not aligned with NASA exploration objectives or future orbital, lunar, or Martian operational needs.

5.2.5 Standards Development Activities: Development of new manufacturing certification standards or broad industrial quality assurance frameworks beyond those necessary to support proposed demonstrations.

6. DELIVERABLES, MILESTONES AND REVIEWS

Offerors shall propose deliverables, milestones and reviews appropriate to the maturity, scope, and technical approach of their proposed efforts. Proposed milestones shall represent meaningful and measurable technical progress. Proposed deliverables shall provide sufficient objective technical evidence to demonstrate progress toward, or achievement of, the stated objectives and outcomes. Proposed reviews and Government insight activities shall provide the Government with opportunities to assess technical progress, performance, technical maturity, and readiness to proceed. The desired deliverables, milestones, and reviews of a successful proposal include:

6.1 Design reviews include preliminary design reviews, critical design review, systems requirements, system design, and demonstration readiness review. Associated review artifacts, data packages, and supporting documentation shall be provided in formats mutually agreed upon during review planning with NASA.

6.2 Terrestrial demonstration of an integrated manufacturing system that extends beyond proof of concept and is representative of a scalable system suitable for mission infusion in the relevant environment.

6.3 Prototype manufacturing hardware, subsystem assemblies, or integrated demonstration systems representative of the proposed ISM architecture.

6.4 Technical reports, briefings and programmatic documentation describing system design, manufacturing processes, integration activities, testing methodologies, performance characterization, operational data, and technical progress, schedule status, and risk posture throughout the period of performance.

6.5 Operational datasets and manufacturing telemetry supporting process validation, anomaly characterization, quality assessment, and future NASA trade studies.

6.6 Test reports documenting manufacturing performance, environmental operation, process repeatability, inspection results, and operational reliability under relevant demonstration conditions.

6.7 Documentation describing pathways for advancing demonstrated manufacturing technologies toward future flight-relevant implementation, including identification of major technical risks, operational constraints, and future maturation needs.

6.8 Programmatic and operational planning documentation supporting execution and lifecycle activities, which may include integrated master schedules, concepts of operations, design guidance for manufacturing capabilities and expected material properties, and risk management approaches appropriate to the proposed effort.

6.9 Government insight activities as appropriate and coordinated with the Government to support technical assessment, collaboration and programmatic visibility throughout the period of performance shall include monthly status reports and meetings, milestone reviews, demonstrations, and site visits. NASA will actively engage with selected Offerors through ongoing technical engagement, milestone reviews, and Government insight and oversight activities to support assessment of technical progress, and achievement of program objectives.

6.10 Final Report (Limited and Unlimited versions. Unlimited versions shall be free from ITAR/EXPORT control and should be able to be shared with the public.)

6.11 Continuation Review: The Contractor shall support a continuation review for each CLIN prior to completion of the CLIN and, when applicable, prior to Government authorization to proceed with the subsequent CLIN. The Contractor shall provide the Government with information sufficient to assess technical performance, schedule status, risk retirement, deliverable status, unresolved issues, technical maturity, and readiness to proceed. The Contractor shall also provide its recommendation regarding continuation. The Government will use the results of the continuation review to inform its decision regarding exercise of the subsequent Option.