Smart Manufacturing for the Space Sector: Integrating Cyber-Physical Systems Across Processes and Facilities

This chapter presents a structured approach for integrating Cyber-Physical Systems (CPS) and Industry 4.0 technologies into Manufacturing, Assembly, Integration, and Testing (MAIT) processes in the space sector. The transition toward the New Space paradigm, characterized by large satellite constellations, higher production rates, and increased customization, requires a shift from traditional, sequential manufacturing toward data-driven and adaptive production ecosystems. Building on the conceptual evolution from Smart Structures to Smart Manufacturing, the proposed methodology supports a stepwise digital transformation grounded in process analysis, digital maturity assessment, and CPS-based architecture design. The framework combines process-level digitalization with facility-level integration, enabling vertical and horizontal data flows across the industrial environment. Two representative industrial case studies are discussed. The first addresses the CPS- enabled automation and monitoring of composite sandwich panel manufacturing for satellite structures, demonstrating improvements in process visibility, traceability, quality control, and predictive maintenance. The second focuses on the digital transformation of an aerospace production facility through a Smart Facility Management System, extending CPS principles beyond the shopfloor to energy systems, logistics, and infrastructure. Together, these cases illustrate how real-time data acquisition, IoT connectivity, and AI-based analytics enhance operational efficiency, scalability, and resilience. The chapter highlights the role of maturity models in defining realistic digitalization roadmaps and emphasizes the importance of human–machine interaction in CPS-enabled environments. Overall, the proposed approach provides a practical and scalable pathway toward Space Factory 4.0, supporting higher productivity, improved quality, and sustainable manufacturing practices in response to the demands of the evolving space economy while ensuring certification and reliability.