Space structures such as the International Space Station experience continuous degradation throughout their operational lifetime due to micrometeoroid impacts, radiation exposure, thermal cycling, and material ageing. Current external inspection approaches rely primarily on astronaut spacewalks and robotic manipulators, which introduce operational risks, require significant resources, and provide limited flexibility. As orbital infrastructure grows in scale and complexity, autonomous inspection systems become increasingly necessary.

This report presents the detailed design of Project EVE, an autonomous inspection system consisting of two free-flying drones designed to inspect large space structures using complementary non-destructive testing methods. The objective is to detect, localise, and characterise structural damage while reducing dependence on human intervention.

The selected architecture employs two specialised vehicles. Alpha performs rapid large-area inspection and identifies regions of interest, while Beta conducts detailed follow-up inspection. Together, the drones combine optical imaging, three-dimensional structured light, infrared thermography, and shearography to enable both surface and subsurface defect detection. To support detailed inspections in orbit, a deployable shading mechanism creates controlled thermal transients without dedicated heating hardware.

The final integrated design demonstrates that autonomous multi-drone inspection can provide a scalable, safer, and operationally flexible alternative to conventional inspection approaches for future long-duration space infrastructure. ... Read more