Robotics is advancing rapidly within the aerospace sector, enabling a new generation of tasks that range from orbital assembly to aircraft inspection. These robotic systems reduce risk, improve efficiency and extend capabilities where human performance would be limited or dangerous. Recent developments in both space and aviation show how robotics is increasingly embedded in aerospace operations.
According to a report by Extrapolate, the global aerospace robotics market size is projected to reach USD 7.87 billion by 2030, growing at a CAGR (compound annual growth rate) of 14.23% between 2023 and 2030. This blog explores ten compelling use cases, drawing on contemporary projects and authoritative sources to highlight the most significant transformations.
Top 10 Aerospace Robotics Market
1. In-Space Assembly and Maintenance
Robotic systems are playing an increasingly central role in assembling large structures in space. NASA’s Jet Propulsion Laboratory (JPL) is actively developing robots for in-space assembly tasks that minimize risk from extra-vehicular activities (EVAs). These robots include highly dexterous limbs, modular tools and algorithms for locomotion on truss structures (Source: www-robotics.jpl.nasa.gov).
Such systems could construct habitats, telescopes or solar arrays in orbit without relying on constant astronaut involvement. The savings in risk and cost are substantial, especially for long-duration missions or large infrastructure deployments.
2. Robotic Inspection of Orbital Structures
Inspecting space station components or large orbital platforms requires precision and autonomy. NASA’s Autonomous Walking Inspection and Maintenance Robot (AWIMR) is under development to crawl across truss structures and panelled surfaces in microgravity.
The robot’s capability to perform visual inspection and maintenance without EVA involvement reduces risk to astronauts and allows more frequent, detailed checks of structural integrity.
3. Satellite Servicing: Refueling and Repair
Extending the operational life of satellites is a key mission for aerospace robotics. NASA’s Robotic Refueling Mission (RRM), together with the Canadian Space Agency’s Dextre robot, is demonstrating in-orbit refueling and servicing capabilities (Source: www.nasa.gov).
In one milestone, Dextre used a wire-cutter tool to remove delicate components. These servicing operations could pave the way for routine repairs, upgrades and fuel replenishment, significantly reducing the need to replace aging satellites.
4. Free-Flying Robotics for Space Station Support
Free-flying robots aboard the International Space Station (ISS) provide autonomous operations, inventory management and cargo movement. NASA’s Astrobee robots operate in microgravity, using air nozzles to manoeuvre and cameras and sensors to navigate and interact.
These robots help astronauts by handling repetitive tasks, reducing their workload and increasing operational efficiency. They also serve as testbeds for autonomy and human-robot interaction in space.
5. Robotic Manipulation for In-Space Structures
Large scale manipulation in space uses robotic arms and manipulators to reposition modules, deploy solar arrays or transfer payloads. According to the International State of Play report on in-space assembly and manufacturing, robotic manipulators of various scales are critical for structural assembly, welding, cutting or construction tasks in microgravity.
These long-reach manipulators support construction of space infrastructure that would be challenging or dangerous for human crews.
6. Maintenance of the International Space Station
The ISS relies on sophisticated robotic systems for maintenance and external servicing. The Mobile Servicing System includes the Canadarm2, a rail-mounted robotic arm, and Dextre, a dexterous manipulator.
Dextre can perform delicate tasks like changing Orbital Replacement Units (ORUs) that would otherwise require EVAs. These operations reduce risk to astronauts and improve station longevity.
7. Autonomous Structural Building in Space
Building structures autonomously in orbit is a frontier for space robotics. NASA researchers demonstrated a team of small robots that autonomously built a lattice structure from modular blocks.
These builder robots, equipped with locomotion, gripping and bolting tools, assembled high-performance structures in a coordinated fashion. Such technology may enable on-orbit manufacturing for habitats, shelters or large trusses.
8. Aircraft Inspection Using Drones
Robotic inspection technologies are increasingly deployed in aviation maintenance. Near Earth Autonomy received funding from NASA to develop drones that perform pre-flight checks of commercial airliners.
These drones fly along prescribed paths, capture detailed visual data and remotely transmit images. The process reduces inspection time from hours to minutes, lowers risk to human inspectors and increases the speed and accuracy of fault detection.
9. Non-destructive Testing of Aircraft Components
Robots in aerospace manufacturing conduct non-destructive testing (NDT) to detect flaws in components. According to the Robotic Industries Association, robots perform ultrasonic inspection of airframes and composite materials.
These systems can detect cracks, delamination or rivet anomalies with high precision. The automation of inspection enhances safety and reduces manual labor for repetitive, high-precision tasks.
10. In-Engine Inspection and Repair
Novel robotic systems are designed to operate inside aeroengines for inspection and repair. Research in robotics includes slender continuum robots capable of navigating narrow, curved combustion chambers and performing maintenance operations. One such design involves a tendon-driven continuum robot that can bend and manipulate inside engine interiors (Source: arxiv.org).
The use of these robots could reduce engine downtime by allowing in-situ inspection and potential repair without full disassembly. Over the long term, this capability can drive efficiency in aircraft servicing and maintenance cycles.
Strategic Implications for Aerospace Industry
Robotics is reshaping both the space and aviation segments of the aerospace industry. In space, robotics reduces dependence on astronaut EVAs, lowers risk and enables longer mission duration. The maturation of satellite servicing promises to extend the life of valuable space assets, cutting replacement costs. In aviation, robotics enhances safety and efficiency in inspections and maintenance, potentially reducing turnaround time and labor costs.
Investment in robotics aligns well with broader aerospace trends, including in-orbit manufacturing, sustainable maintenance and extended satellite lifespans. Financial and regulatory support for these technologies will accelerate their operational deployment. Training for robotics, control systems, autonomy and maintenance will also become more valuable as these systems become central to aerospace operations.
Challenges and Considerations
Deploying robotics in aerospace involves technical, operational and regulatory challenges. In-space assembly and servicing must account for communication latency, reliability and fault tolerance. Robots operating in microgravity or outside the station must be resilient to harsh environmental conditions. For aviation inspections, regulatory acceptance of autonomous drones and safety certification remain hurdles. Integration of robotics into existing maintenance workflows requires change management, training and standardization.
Supply-chain limitations and development costs for highly specialized robots also pose constraints. Continuum robots or highly articulated manipulators involve complex design and materials. A focus on modular robotics, robust verification and scalable manufacturing will be critical to widespread adoption.
Outlook
Robotics in aerospace will continue to expand across the ten use cases described here while branching into novel areas. In-space construction may evolve toward autonomous factories, large-scale orbital habitats, or self-repairing spacecraft. Satellite servicing may grow into full life-extension services, involving refueling, module replacement or even deorbiting. Aviation inspections may be fully automated, integrated into predictive-maintenance systems, using fleets of inspection drones and ground robots. Robots are likely to combine with AI, digital twins and teleoperation to create hybrid systems capable of autonomous decision-making and remote human oversight.
Collaboration between space agencies, robotics companies and aerospace manufacturers will deepen. Standardization of interfaces, hardware modules and control architectures will facilitate broader deployment. As robotics technologies mature and costs decline, these use cases will shift from demonstration programs to operational norms, underpinning safer, more efficient and more ambitious aerospace missions.
Conclusion
Aerospace robotics has moved beyond proof-of-concept. The ten use cases detailed above illustrate how robots now help build, inspect, maintain and service aircraft and spacecraft. In-space assembly, satellite servicing, autonomous inspection and in-engine repair all represent real, ongoing projects backed by agencies like NASA. These developments are transforming aerospace operations, reducing risk, increasing resilience and unlocking new mission capabilities. Continued investment and standardization will determine how rapidly these robotic systems become an integrated part of aerospace infrastructure and how far they will drive innovation in future missions.
