Building satellites in the future could be as easy as sending robots packed with hardware into orbit, if a new project from Darpa takes off.

Under its new Phoenix program, which recently completed Phase 1 testing, Darpa is totally rethinking how the U.S. builds and maintains its satellite fleet. The idea is for robots to assemble modular satellite architecture, called satlets, that weigh about 15 pounds and contain the satellite functionality such as the power supply, controls and sensors. All of this is delivered on the Payload Orbital Delivery (POD) system, which is meant to be easily and quickly deployable.

Image: Darpa

"Phase 1 not only showed the feasibility of our robotic tools and assembly techniques, but also validated the concept that we could build new satellites on orbit by physically aggregating satlets in space," said David Barnhart, Darpa program manager, in a statement. "These successes could eventually lead to the revolutionary ability to create new, truly scalable space systems on orbit at a fraction of current costs."

As it stands now, satellites are very expensive, carry a long developmental lead time and they have to be designed to endure their time in orbit without any upgrades or repairs, all of which ultimately determines the size, complexity and cost of the satellite. In the end, satellites sent into geosynchronous orbit, 22,000 miles above Earth, are essentially unreachable with currently available technology.

The technologies that comprise the Phoenix program "could help satellites reach new or proper orbits, inspect satellites as part of routine maintenance or troubleshooting efforts, repair or replace worn-out components, or add or upgrade capabilities," said Barnhart. "These capabilities would enable space systems, for the first time, to have the flexibility, accessibility and resilience that designers of terrestrial systems take for granted."

For Phase 2 of Phoenix, Darpa has awarded eight contracts to companies including Busek, Honeybee Robotics and Oceaneering.

Last year, Darpa announced a breakthrough in satellite technology by developing a gigantic satellite made out of durable plastic that would unfold into a 68-foot wide satellite capable of covering 40 percent of the earth's surface.