On Wichita State University Week: Reducing lift-off weight can be crucial for spaceflight.

Waruna Seneviratne, director of the Advanced Technologies Lab for Aerospace Systems (ATLAS) at the National Institute for Aviation Research, explores one way to do so.

Faculty Bio:

Waruna Seneviratne is the Director of the Advanced Technologies Lab for Aerospace Systems (ATLAS) at the National Institute for Aviation Research (NIAR), Wichita State University. With over 25 years at NIAR, he leads a diverse research portfolio in advanced manufacturing, inspection, durability, damage tolerance, certification, and aging of composite aircraft structures—supported by agencies including the FAA, DoD, DHS, NASA, and major aerospace manufacturers.

In 2019, he founded the NIAR ATLAS Manufacturing Innovation Center to create a makerspace-style environment for accelerating advanced manufacturing research and prototyping. He also leads the Manufacturing for Affordable Sustainable Composites (MASC) initiative, sponsored by the Air Force Research Lab, which focuses on integrating in-process inspection technologies into manufacturing. His team’s automated fiber placement (AFP) inspection system received the 2023 JEC Composites Innovation Award for Digital, AI & Data. In 2024, his work on thermoplastic injection overmolded aircraft window plugs—adapting automotive technologies for high-rate aerospace production—earned both the Best Technical Paper Award at SAMPE and the CAMX Innovation Award.

Waruna serves on the Technical Oversight Committee for NASA’s Advanced Composites Consortium (HiCAM) and the Executive Steering Committee for the Office of Naval Research’s Composites Manufacturing Technology Center through The Composites Consortium. He is a recipient of NASA’s Group Achievement Award (2022) for his contributions to the Advanced Composites Project, and the “Turning Goals into Reality” Honor Award (2002) for his work with the AGATE Alliance.

Before joining NIAR, Waruna worked as a stress analyst on the Airbus A380 program, ensuring compliance with FAA and EASA certification standards. He holds BS, MS, and PhD degrees in Aerospace Engineering from Wichita State University and has lived in Wichita for over 30 years.

Transcript:

Today’s space structures are built to survive one of the most violent environments imaginable—launch. As a result, they are often overdesigned, carrying extra mass, cost, and complexity just to endure those few critical minutes. At the same time, everything we send to space must fit within the space of a payload bay. This constraint forces engineers to fold structures into compact, origami-like forms—packed with joints, motors, and deployment mechanisms that add weight, introduce risk, and create potential points of failure.

But what if we didn’t have to build everything on Earth?

What if we could build them in space instead?

To meet this challenge, a new approach is emerging: Automated Tool-less Manufacturing, or AToM. This system uses two coordinated robotic arms to fabricate high-performance thermoplastic composite structures directly in space. Working together, they place continuous fibers with precision, creating strong, lightweight, three-dimensional parts—without molds, without ovens or autocalves, and without the constraints of traditional manufacturing.

Think of it as additive manufacturing—but engineered for structural strength with continuous fiber composites.

The impact is transformative. By eliminating tooling and reducing dependence on multiple launches, AToM removes traditional limits on size, weight, and complexity. Structures no longer need to fold or deploy—they can be built exactly as designed, with fewer joints and far less mechanical complexity and weight.

And this isn’t theoretical. At the NIAR ATLAS Manufacturing Innovation Center, this technology has already demonstrated the ability to rapidly produce aerospace-quality composite structures on-site.

Even more, the thermoplastic materials used are recyclable—opening the door to a circular manufacturing economy in space, where every resource matters.

From orbit to the Moon, to Mars and beyond, this technology redefines not just how we build—but where we build.

Read More:

Advanced Technologies Lab for Aerospace Systems - ATLAS

New Technology Can Create Composite Structures in Space

In-Situ Consolidation Thermoplastic Process Development for Toolless Automated Fiber Placement Manufacturing in Space

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Waruna Seneviratne, Wichita State University - Automated Toolless Manufacturing of Composite Structures in Space

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Waruna Seneviratne, Wichita State University - Automated Toolless Manufacturing of Composite Structures in Space