A Novel Dispenser-based Assembly Concept for a Hexagonal SBSP Array

Space-based solar power (SBSP) is a promising technology for delivering renewable energy by capturing sunlightin space and transmitting the power to Earth. Constructing the very large arrays and reflectors required for SBSPremains challenging, as conventional robotic assembly would demand precise, failure-free operations in the harsh spaceenvironment. A simpler and more robust approach is therefore needed.This paper investigates a dispenser-based method for assembling hexagonal SBSP tiles. The dispenser stores a stackof passive tiles in a semi-open harbour and releases them sequentially in a controlled manner. Each tile is designed withguide tracks and embedded magnets to self-align and lock into position, enabling structural stability without complexdocking procedures.Two dispensing mechanisms were developed and compared under identical test conditions: (1) a solenoid kicker,which propels each tile forward into the array, and (2) a four-bar pusher linkage, which advances the entire row whileinserting a new tile at the front. Experiments were conducted on a flat table with the same tile design and protectivecover, comprising two phases: Experiment 1, linear assembly of a six-layer array, and Experiment 2, replacement ofintentionally missing tiles. Results show that the pusher achieved a 100 % success rate in assembling continuous single-row arrays and can also replace missing tiles when only a single row is present. However, once multiple adjacent rowsare integrated, neighbouring edges prevent the row from advancing and the pusher can no longer perform replacements.The kicker achieved reliable gap-filling up to the third layer (100 % success in layers 2–3) but suffered frequent placementfailures beyond that point, limiting its ability to complete large arrays.These findings indicate that the pusher provides highly reliable primary assembly for long linear segments, while thekicker offers a limited fault-tolerant capability for correcting local defects. Future work will scale the system to largerarrays, refine the dispenser and tile design to address current geometric constraints, and conduct tests in simulatedmicrogravity environments to validate feasibility for full-scale orbital SBSP deployment