In-orbit refueling
Transferring propellant to a satellite in orbit via a dedicated vehicle, to extend its maneuverability without replacing or deorbiting the spacecraft.
In-orbit refueling refers to the transfer of propellant, typically hydrazine or an equivalent propellant, from a dedicated servicing vehicle to a client satellite running low on reserves, extending its useful life without resorting to in-orbit servicing, which takes over propulsion without transferring any fuel. The operation requires precise docking between two objects never designed to couple, with a risk of transfer failure, leakage or valve incompatibility that can damage both spacecraft. For insurers, this new technical risk compounds an unprecedented valuation question: a refueled satellite changes its risk profile and insured duration without any change to its bus or payload, shifting actuarial analysis away from periodic replacement and toward the continuous maintenance of an orbiting asset. The market remains young and commercial refueling capacity still scarce, which for now limits the number of policies concerned but signals future growth as satellites are increasingly designed with standardized refueling interfaces from the outset of manufacturing.
In May 2007, DARPA's Orbital Express mission carried out the first robotic hydrazine propellant transfer in orbit, from the ASTRO servicing vehicle to the NextSat client satellite, demonstrating the technical feasibility of autonomous refueling fifteen years before the first commercial offerings.
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