Orbit Rob unveils 'Helios' 4-arm space robot with 3D-printed components for zero-gravity maintenance

ETH Zurich spinout Orbit Robotics has unveiled Helios, a four-arm humanoid robot designed specifically for zero-gravity environments aboard space stations. The robot uses a tendon-drive system inspired by human musculature, replacing traditional rotary actuators with belts and pulleys to reduce mass and increase flexibility. Critical load-bearing components are 3D-printed, enabling rapid iteration and simplified in-space maintenance. Helios is currently undergoing ground-based simulations of orbital conditions, though it has not yet completed zero-gravity flight tests.

This development sits at the intersection of two converging trends: the growing need for autonomous in-orbit servicing and the increasing maturity of additive manufacturing for space-grade hardware. Helios targets the roughly 35% of astronaut time currently consumed by maintenance and inventory tasks, aiming to automate those functions. The use of 3D-printed structural parts is notable not for novelty - space agencies have used AM for brackets and housings for years - but for the design freedom it provides in a robot with four articulated limbs and five-fingered hands. The tendon-drive approach, which moves motors closer to the shoulder joints to minimize moving mass, addresses a persistent challenge in space robotics: balancing dexterity with energy efficiency in microgravity.

For Orbit Robotics, the path to deployment involves more than hardware refinement. The team has developed the Ikarus platform for autonomous navigation, remote control, and imitation learning, which will determine whether Helios can operate reliably in the constrained, safety-critical environment of a space station. The real test will be transitioning from ground simulations to actual microgravity validation, followed by integration with existing station workflows. If Helios can demonstrate consistent performance in those conditions, it could become a reference design for how AM-enabled robotics reduce the logistical burden on crewed missions.