Thu, 04 December, 2025
TWI has joined with the University of Leicester for the ISPARK project to develop a robot-mounted arc welding system for in-space repair, joining and future orbital manufacturing.
Funded by the UK Space Agency’s National Space Innovation Programme (NSIP), ISPARK (the Intelligent SPace Arc welding Robotic Kit), will be the UK’s first in-space robotic welding capability.
This project directly supports the ambitions of the UK’s National Space Strategy and the ISAM (In-Space Servicing, Assembly and Manufacturing) roadmap.
Speaking on ISPARK, TWI Section Manager Dr Nick Ludford said, “TWI is pleased to be partnering with the University of Leicester on this pioneering effort. Applying advanced welding technologies to the challenges of space is a natural extension of our expertise, and ISPARK provides a unique opportunity to help develop a capability that will be vital for future in-orbit repair and construction.”
Welding in space faces a number of significant challenges, including the vacuum environment, microgravity, and thermal instability, as well as the inherent danger and intense physical demands placed on astronauts. These challenges have meant that performing welds in space is a rare and technologically challenging undertaking. The ISPARK project aims to overcome these challenges through the creation of a new, space-qualified robotic welding capability that enables autonomous, in-orbit repair and manufacturing.
Vacuum environment trials will check the performance of the welding system, while digital twin modelling simulations will provide additional data that will help validate key technologies before eventual use in the more complex thermal, radiative and dynamic conditions of real spaceflight.
TWI’s expertise in welding and materials will be combined with the University of Leicester’s experience and knowledge of AI-powered robotics, autonomous control, space engineering and digital-twin weld modelling
Principal Investigator Dr Daniel Zhou Hao, from the University of Leicester School of Computing and Mathematical Sciences, said, “ISPARK advances the UK’s and the world’s capability for in-space repair and manufacturing. By combining Leicester’s strengths in AI robotics and space engineering with TWI’s world-leading welding expertise, we are developing an enabling technology that could redefine how large structures are built and maintained in orbit.”
Members of the ISPARK project team from the University of Leicester and TWI meet at Space Park Leicester
This project comes as the UK Space Agency has announces £17 million of funding for seventeen UK space projects through its National Space Innovation Programme (NSIP). Unveiled at Space Comm Expo in Glasgow, the selected projects span five strategic themes; space domain awareness, in-orbit servicing and manufacturing, Earth observation, satellite communications, and position, navigation and timing.
Together, these projects will deliver transformative technologies to enhance climate monitoring, improve connectivity, enable sustainable satellite operations, and strengthen national security. From quantum communications and robotic servicing tools to AI-powered pollution tracking and refuellable propulsion systems, these innovations will help build a resilient, competitive UK space sector.
Space Minister Liz Lloyd explained, “Space technology benefits people’s lives every day – from checking the weather to navigating your car journey home from work. This funding backs the brilliant UK innovators developing the next generation of space technology,” adding, “By supporting our space sector, we’re strengthening the UK’s position as a world leader in space innovation and building technologies that will benefit people across the country for years to come.”
We are looking forward to using our expertise, experience and technical excellence to help meet the aims of this innovative and transformative new project for space.
To find out more, please email contactus@twi.co.uk.