China Advances On-Orbit Manufacturing of CF/PEEK Composite Space Structures

Published date:09/05/2026 | Last updated date:09/05/2026

China’s Shenyang Institute of Automation, Chinese Academy of Sciences (SIA CAS) has reported progress in on-orbit manufacturing technology for carbon fiber-reinforced PEEK composite structures, a development that could support the automated assembly of large space systems beyond Earth.

The research, published in Space: Science & Technology, combines pultrusion molding of CF/PEEK tubular units with laser transmission welding using 3D-printed PEEK joints. The goal is to create an integrated method for producing and joining lightweight composite structural elements directly in space.

Targeting large structures that cannot be launched fully assembled

Large space structures such as antennas, solar power stations and future lunar base components face a basic constraint: many are too large or complex to launch as fully assembled hardware.

SIA CAS’ approach addresses two core requirements for on-orbit construction:

• efficient fabrication of strong composite tubular units
• reliable connection between those units after forming

The team studied how temperature and pultrusion speed affect the mechanical properties of CF/PEEK tubes, then used those findings to define process parameters for high-specific-strength, high-stiffness structural units.

Laser welding replaces weaker joining routes

For the joining stage, the researchers used 3D-printed translucent PEEK joints and laser transmission welding to connect composite tubes into larger assemblies.

This method is important because traditional joining routes can create problems in space structures:

• adhesive bonding may age or degrade
• mechanical fasteners add weight
• bolted joints can create stress concentration
• manual assembly is difficult in orbital environments

Laser transmission welding offers a noncontact, efficient joining method with more uniform stress distribution and fewer added components. The study reports that the welded joints met structural load-bearing requirements for the demonstrator.

Prototype antenna truss validates the process chain

To test the concept, the team manufactured a scaled-down parabolic antenna framework by cutting CF/PEEK composite tubular units into different lengths and joining them into a truss structure.

That prototype demonstrated the full chain:

• material preparation
• pultrusion molding
• tube cutting
• joint fabrication
• laser welding
• structural assembly

This matters because on-orbit construction depends not on a single material breakthrough, but on the ability to link manufacturing, joining and assembly into one repeatable process.

Why CF/PEEK is suited for space construction

CF/PEEK thermoplastic composites offer several advantages for orbital structures:

• high strength-to-weight ratio
• high stiffness
• good thermal resistance
• strong environmental durability
• weldability compared with thermoset composites

The weldability point is especially important. Thermoplastic composites can be reheated and fused, making them more suitable for automated assembly and repair than conventional thermoset composites.

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Editorial perspective

This development is significant because it points toward a different model of space infrastructure.

Instead of designing every large structure to survive launch as a finished assembly, future systems may be built from standardized composite units manufactured and joined in orbit.

For the composites industry, the key lesson is clear: thermoplastic composites are becoming more than lightweight structural materials. Their ability to be welded, reshaped and integrated into automated assembly processes may make them central to the next generation of space construction.