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Viewgraphs on the Pathfinder program are presented. Information is given on technology needs, a planetary rover, program management, an autonomous lander, mission applications, orbital assembly, cryogenics, space nuclear reactors, space manufacturing, optical communications, spacecraft propulsion, aerobraking, and orbital transfer vehicles.
A models lunar mining method is proposed that illustrates the problems to be expected in lunar mining and how they might be solved. While the method is quite feasible, it is, more importantly, a useful baseline system against which to test other, possible better, methods. Our study group proposed the slusher to stimulate discussion of how a lunar mining operation might be successfully accomplished. Critics of the slusher system were invited to propose better methods. The group noted that while nonterrestrial mining has been a vital part of past space manufacturing proposals, no one has proposed a lunar mining system in any real detail. The group considered it essential that the design of actual, workable, and specific lunar mining methods begin immediately. Based on an earlier proposal, the method is a three-drum slusher, also known as a cable-operated drag scraper. Its terrestrial application is quite limited, as it is relatively inefficient and inflexible. The method usually finds use in underwater mining from the shore and in moving small amounts of ore underground. When lunar mining scales up, the lunarized slusher will be replaced by more efficient, high-volume methods. Other aspects of lunar mining are discussed.
We will present a review of recent laboratory results obtained in dry magnetic separation of one gram samples of the minus 1 mm size fraction of five lunar soils of widely differing maturities. Two highland soils were investigated as potential sources of low iron content feed stocks for space manufacture of metals, including aluminum, silicon, and calcium. Pure anorthite was separated from the diamagnetic fraction of immature highland regolith. Three high titanium mare soils were investigated as potential sources of ilmenite for production of hydrogen and for recovery of He-3. Ilmenite and pyroxene were separated from the paramagnetic fractions of the mare basalts. Agglutinates and other fused soil components containing metallic iron were separated from the strongly magnetic fractions of all soils. We will present conceptual magnetic separation flow sheets developed from the laboratory data and designed for production of anorthite from highland soils and for production of ilmenite from mare soils. Using these flow sheets, we will discuss problems and opportunities associated with the magnetic separation of lunar soils. Separation of high-grade anorthite or other diamagnetic components at moderately high recovery can be achieved in processing immature highland soils. Further, while magnet weight is always an issue in magnetic separation technology, recent developments in both low temperature and high temperature superconductivity present unusual opportunities for magnet design specific to the lunar environment.
Space based materials processing experiments can be enhanced through the use of IVA robotic systems. A program to determine requirements for the implementation of robotic systems in a microgravity environment and to develop some preliminary concepts for acceleration control of small, lightweight arms has been initiated with the development of physical and digital simulation capabilities. The physical simulation facilities incorporate a robotic workcell containing a Zymark Zymate II robot instrumented for acceleration measurements, which is able to perform materials transfer functions while flying on NASA's KC-135 aircraft during parabolic manuevers to simulate reduced gravity. Measurements of accelerations occurring during the reduced gravity periods will be used to characterize impacts of robotic accelerations in a microgravity environment in space. Digital simulations are being performed with TREETOPS, a NASA developed software package which is used for the dynamic analysis of systems with a tree topology. Extensive use of both simulation tools will enable the design of robotic systems with enhanced acceleration control for use in the space manufacturing environment.
This paper is the first in a series of symposia presenting research activity in microgravity fluid mechanics. General topics addressed include two-phase flow and transport phenomena, thermo-capillary flow, and interfacial stability. Papers present mathmatical models of fluid dynamics in the microgravity environment. Applications suggested include space manufacturing and storage of liquids in low gravity.
This volume contains abstracts that have been accepted for presentation at the Space Resources Utilization Roundtable, October 27-29, 1999, in Golden, Colorado. The program committee consisted of M. B. Duke (Lunar and Planetary Institute), G. Baughman (Colorado School of Mines), D. Criswell (University of Houston), C. Graham (Canadian Mining Industry Research Organization), H. H. Schmitt (Apollo Astronaut), W. Sharp (Colorado School of Mines), L. Taylor (University of Tennessee), and a space manufacturing representative. Administration and publications support for this meeting were provided by the staff of the Publications and Program Services Department at the Lunar and Planetary Institute.
Contents include the foloving: 1. In-Situ Resource Utilization. Using regolith. 2. In-Space Manufacturing. Fabricating materials. 3. Radiation Protection Methods. Developing habitat concepts. 4. Radiation Physics. Measuring radiation transmission.
Theoretically, the strength of glass processed in vacuum should be higher due to outgassing of contaminants normally present in the glass, such as bulk water in the form of OH bonds that tends to weaken the glass structure. In this research, small discs of a few types of glass have been subjected to various temperatures for extended periods of time in vacuum. Their strength was then tested using a standard flexure technique, facilitated by a custom-designed test fixture, and the results were compared to glass tested in air using the same fixture. The purpose of the glass blowing investigation was to prove the basic feasibility of a high-level concept for in-space manufacture of optical elements. The central requirement was that the glass bubble had to be blown into a support structure such that the bubble could be handled by manipulation of the structure. The blown bubble attached itself to a mullite ring geometrically and mechanically, as a demonstration in the initial experiments described here, by expanding through and around it. The vacuum system used was custom made, as were most of the components of the system, such as the heating element, the glass and ring support structure, and the gas inlet system that provided the pressure needed to blow the glass.
The development of the Bi-Axial Solar Array Drive Mechanism (BSADM) presented in this paper is a demonstration of SSTL's unique space manufacturing approach that enables performing rapid development cycles for cost-effective products that meet ever-challenging mission requirements: The BSADM is designed to orient a solar array wing towards the sun, using its first rotation axis to track the sun, and its second rotation axis to compensate for the satellite orbit and attitude changes needed for a successful payload operation. The tight development schedule, with manufacture of 7 Flight Models within 1.5 year after kick-off, is offset by the risk-reduction of using qualified key component-families from other proven SSTL mechanisms. This allowed focusing the BSADM design activities on the mechanism features that are unique to the BSADM, and having an Engineering Qualification Model (EQM) built 8 months after kick-off. The EQM is currently undergoing a full environmental qualification test campaign. This paper presents the BSADM design approach that enabled meeting such a challenging schedule, its design particularities, and the ongoing verification activities.
Microgravity based commercial opportunities are broad, with applications ranging from fiber optics, device-grade semiconductor crystals, space beads, new materials, cell micro encapsulation, 3D tissues and cell cultures, genetic and molecular changes of immune suppression, protein and virus crystal growth, perfume and hair care. To date, primarily the knowledge gained from observing and understanding new end states of systems unraveled in microgravity has been translated into unique technologies and business opportunities on Earth. In some instances existing light qualified hardware is immediately available for commercial RD for small scale in-space manufacturing. Overall products manufactured in microgravity have key properties usually surpassing the best terrestrial counterparts. The talk will address the potential benefits of microgravity research for a variety of terrestrial markets. Our findings originate from discussions with 100+ non-aerospace private companies among the high-tech Silicon Valley ecosystem, show that the opportunities and benefits of using the ISS are largely not considered by experts, primarily due to a lack of awareness of the breadth of terrestrial applications that have been enabled or enhanced by microgravity RD. Based on this dialogue, the concept of microgravity verticals is developed to translate the benefits of the microgravity environment into blue ocean business opportunities for various key US commercial sectors.
Asteroids contain a wealth of resources including water and precious metals that can be extracted. These resources could be applied to in-space manufacture of products that depend less on material launched from Earth's surface. The Meteoroid Impact Detection for Exploration of Asteroids (MIDEA) concept addresses the challenge of characterizing an asteroid surface using a small satellite with a constellation of free-flying plasma sensors to assess the asteroid’s viability for in situ resource utilization (ISRU). The plasma sensors detect ions ejected from the surface of an asteroid by meteoroid impacts, enabling the surface composition to be inferred. The objective of this NIAC Phase I study was to demonstrate feasibility of the MIDEA architecture in the context of proximity operations around an asteroid target and to develop the design of an orbital geometry and attitude control strategy for the ultralight plasma sensors. This was undertaken through a simulation framework to identify and characterize a favorable orbit for the MIDEA sensor constellation, and developing a sensor geometry that is consistent with maintaining the pointing requirements necessary to operate with sufficient power generation. Our study showed that a polar orbit aligned along the asteroid terminator provided sufficient stability for the sensors in the low gravitational environment under the influence of substantial solar radiation pressure. Reflector vanes using controlled reflectivity devices implemented with liquid crystal technology are capable of maintaining the sensor attitude so that it consistently points its solar panels in the sun direction and the sensor electrode at the asteroid surface. Finally, the reduction in meteoroid impact detection due to visibility constraints from the proposed orbit does not substantially extend the expected mission duration. These results indicate that the MIDEA concept can be achievable using a 10–20 kg spacecraft, which would be able to characterize the surface composition of an asteroid within 30–50 days of proximity operations. This architecture, implemented in parallel to multiple asteroid targets, would enable widespread exploration of near-Earth asteroids at low cost.
Presentation will highlight the Space Shuttle Program Lessons Learned with a simulation of the complexity, volatility and multi-functional relationships of the supplier base followed by a review of a key element in the NASA KSC Supply Chain/Logistics Strategic Roadmap to include supply chain resiliency modeling as impacted by 3D Printing technology maturation and campaign-level network flow modeling for logistics nodal positioning of critical product needed to support space operations and In-Space Manufacturing beyond Low Earth Orbit.
For practical, economical, and sustainable human missions to the Moon, processing of lunar regolith and metal oxides is necessary for localized production of oxygen (O2) and metals that can be repurposed as rocket propellant, life support O2, and in-space manufactured parts. The primary candidates for in-situ resource utilization (ISRU) regolith processing are carbothermic reductions and molten regolith electrolysis (MRE) which both produce oxygen and a reduced, deoxygenated metallic slag. A metal separation technique is still required to capture and purify metals from the deoxygenated slag for reuse in areas such as metallic part fabrication, structural or design frameworks, and metal catalyst production. The Marangoni Effect is best explained as mass transfer along an interface driven by surface tension gradients induced by temperature and concentration differences. Due to the temperature gradients, molten metal can be transported in this fashion to create thin films. This method can transport molten metal in the absence of gravity or mechanical motion and greatly increases the available surface area for a vacuum fractional separation process. In this study, a novel vacuum furnace induces the Marangoni Effect to fractionally decompose and separate valuable metals (e.g., aluminum) from thin films of molten metal via vacuum distillation. The proposed work will examine lunar regolith, metal-based recycling feedstocks, and metallic slags produced from the carbothermal reduction of regolith. Data and observations from this study could produce a simple yet effective method of refining lunar derived metals by taking advantage of the high vacuum environment present on the lunar surface.
The primary objective for this effort is to fabricate and characterize redox-active molecules using CVD graphene as working electrodes using standard "on-chip" lithographic techniques. We then plan to move away from “on-chip” graphene electrodes and study methods for CVD graphene transfer that can also accommodate in-space manufacturing (ISM), enabling the use of this technology for crewed mission operations of the future.
Most human missions in space have been brief, lasting only days or weeks, and they have taken all the materials they need. Using the alternate method, the International Space Station recycles water and oxygen, and it is often assumed that future Moon and Mars missions should also recycle their life support materials. The “take or make” decision is primarily based on cost, and making or recycling material on longer space missions can sometimes be less expensive than taking it. Longer missions favor recycling over resupply when the initial cost to provide recycling equipment is less than the cost to provide resupply. Recycling was clearly cheaper than taking material to the space station in the space shuttle era when launch costs were very high. Launch costs have decreased and the take or make decision point has changed. The recent reduction in launch cost by a factor of about twenty-five to fifty makes taking material cost less than making or recycling it for much longer missions. The cost breakeven point when making rather than taking material is less expensive is now much farther out in time than before. Material recycling or in situ production no longer saves cost except for very large or very long missions.
Most human missions in space have been brief, lasting only days or weeks, and they have taken all the materials they need. Using the alternate method, the International Space Station recycles water and oxygen, and it is often assumed that future Moon and Mars missions should also recycle their life support materials. The “take or make” decision is primarily based on cost, and making or recycling material on longer space missions can sometimes be less expensive than taking it. Longer missions favor recycling over resupply when the initial cost to provide recycling equipment is less than the cost to provide resupply. Recycling was clearly cheaper than taking material to the space station in the space shuttle era when launch costs were very high. Launch costs have decreased and the take or make decision point has changed. The recent reduction in launch cost by a factor of about twenty-five to fifty makes taking material cost less than making or recycling it for much longer missions. The cost breakeven point when making rather than taking material is less expensive is now much farther out in time than before. Material recycling or in situ production no longer saves cost except for very large or very long missions.
This work synergized state-of-the-art trash-to-gas (TtG) and in-space manufacturing (ISM) technologies to successfully extract metals from astronaut waste items for use in 3D printing. This was accomplished by isolating pure aluminum (Al 1235) from astronaut multilayer food packaging via TtG processing, cleaning the extracted aluminum, and preparing it for compatibility with the bound metal deposition (BMD) 3D printing process. A suite of material analyses was performed on the extracted aluminum product to fully characterize the key properties linked to effective additive manufacturing, including particle size distribution, oxygen content quantitation, and elemental composition. Metal extraction from Lunar and Martian regolith has become a significant area of interest for the in-situ resource utilization (ISRU) community to produce metallic equipment for various mission scenarios. However, the extraction of metals from astronaut waste streams has yet to be investigated. This project demonstrated an end-to-end waste metallic reuse process which may garner considerable metal production that would otherwise be disposed of.
An attempt is made to provide pertinent and readily usable information on the extraterrestrial processing of materials and manufacturing of components and elements of these planned large space systems from preprocessed lunar materials which are made available at a processing and manufacturing site in space. Required facilities, equipment, machinery, energy and manpower are defined.