Texas A&M University doctoral student Sarah Downs is advancing space-based robotics by developing algorithms that allow machines to perform complex assembly tasks without relying on camera-based vision systems. By utilizing force-feedback sensors, her research addresses the “peg-in-hole” challenge of satellite construction in the harsh, zero-gravity environment of outer space, where traditional optical sensors may experience malfunctions or signal delays. Her work, conducted in collaboration with NASA, focuses on enabling robotic manipulators to “feel” their way through assembly processes to ensure precision in remote, extraterrestrial settings.
Engineering Precision in Zero Gravity
The core of Downs’s research involves a force-based insertion process that replaces the dependency on vision systems. In traditional satellite assembly, robots often rely on cameras to guide components into place. However, as noted in her research, the remote and unpredictable nature of space can render camera systems unreliable. According to details provided by the IEEE, Downs’s approach uses torque sensors on a robotic gripper to detect the physical resistance—or force feedback—of an antenna as it moves toward a satellite’s interface. This allows the robot to determine the correct position and orientation of parts based on physical contact rather than visual input.
Operating in zero gravity adds a significant layer of technical complexity. Because there is no gravity to anchor the equipment, any force exerted by the robotic arm can cause the satellite itself to shift or drift. Downs’s research involves calculating the necessary reverse thrusts required to counter these reaction torques. By applying these specific calculations, the robot can maintain its position while successfully completing the insertion, mitigating the risk of the satellite being pushed away by the force of the assembly process.
From Tulsa to the Robotics and Automation Design Lab
Downs’s path to space robotics began with an early interest in STEM, nurtured by her participation in the First Lego League during her middle school years in Tulsa, Oklahoma. Her academic career progressed through the University of Tulsa, where she earned a bachelor’s degree in electrical engineering in 2024. During her undergraduate studies, she gained hands-on experience through a capstone project that involved building a lunar lander exhibit for the Tulsa Air and Space Museum, which remains on display for visitors.
She is currently a doctoral student at Texas A&M University, where she works within the Robotics and Automation Design (RAD) Lab. The lab, established in 2022 and led by NASA veteran Robert Ambrose, specializes in creating technology capable of surviving extreme environments. The facility is currently expanding its footprint with a new space institute scheduled to open in Houston, located in close proximity to the NASA Johnson Space Center.
The Role of Professional Networks in Engineering
Beyond her research, Downs has been a vocal advocate for student involvement in professional organizations. During her time at the University of Tulsa, she served as president of the local IEEE student branch from 2022 to 2024. Under her leadership, the organization expanded its programming, moving from occasional meetings to a bi-weekly schedule that included technical workshops on soldering, 3D printing, and CAD modeling. These efforts resulted in a significant increase in the branch’s executive board membership, which grew from five to 25 students by 2023.
Downs emphasizes that technical skills alone are often insufficient for students entering the job market. She encourages undergraduates to participate in research teams and pursue internships to build tangible proof of their capabilities. Her own professional development included facilities engineering internships at the American Airlines maintenance facility at Tulsa International Airport and electrical engineering roles at Flight Safety International. She suggests that students utilize accessible tools, such as the Raspberry Pi, to engage in personal passion projects that demonstrate their technical proficiency to potential employers.
What Happens Next
As part of the Robotics and Automation Design Lab, Downs continues to refine her doctoral thesis on satellite manipulation.
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