FY23 Relevant Environment Additive Construction Technology Annual Review Presentation
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Lunar Shelter↗
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Lunar Shelter↗
Application of Regolith Polymer Composite Fused Granular Fabrication Construction in Simulated Lunar Conditions
NASA’s Artemis program has the goal of creating a sustained lunar presence to provide unprecedented opportunities for scientific discovery and to ensure industry’s access to the unlimited resources and commercial potential in space. To achieve this goal, NASA must incrementally develop and expand its capabilities beyond the short lunar stays of the Apollo program to a robust continued presence with infrastructure and equipment to reduce mission risk. Kennedy Space Center’s Granular Mechanics and Regolith Operations laboratory (a.k.a. Swamp Works) has partnered with SpaceFactory and LERA Consulting Structural Engineers to develop the architectural and structural design of a robotically constructable unpressurized shelter. The shelter, called Lunar Infrastructure Asset (LINA), is designed to protect astronauts and surface assets from radiation, meteoroid impact, thermal gradients, and to withstand moonquakes. A Fused Granular Fabrication (FGF) construction process using regolith polymer composites was developed. The construction system and associated print parameters are discussed along with the environmental simulation equipment and a summary of test conditions. Test samples were printed in dirty thermal vacuum conditions (~10-3 torr, ~-200 °C,) and subscale versions of LINA were printed on a regolith simulant substrate in vacuum (~10-4 torr). Full scale LINA design optimization, simulation, and construction concept of operations are discussed.
lunar infrastructure↗
Selection, Production and Properties of Regolith Polymer Composite for Lunar Construction
NASA’s Artemis program has the goal of creating a sustained lunar presence to provide unprecedented opportunities for scientific discovery and to ensure industry’s access to the unlimited resources and commercial potential in space. To achieve this goal, NASA must incrementally develop and expand its capabilities beyond the short lunar stays of the Apollo program to a robust continued presence with infrastructure and equipment to reduce mission risk. Kennedy Space Center’s Granular Mechanics and Regolith Operations laboratory (a.k.a. Swamp Works) has partnered with SpaceFactory and LERA Consulting Structural Engineers to develop the architectural and structural design of a robotically constructable unpressurized shelter. The shelter, called Lunar Infrastructure Asset (LINA), is designed to protect astronauts and surface assets from radiation, meteoroid impact, thermal gradients, and to withstand moonquakes. A Fused Granular Fabrication (FGF) construction process using regolith polymer composites was developed. The construction system and associated print parameters are discussed along with the environmental simulation equipment and a summary of test conditions. Test samples were printed in dirty thermal vacuum conditions (~10-3 torr, ~-200 °C,) and subscale versions of LINA were printed on a regolith simulant substrate in vacuum (~10-4 torr). Full scale LINA design optimization, simulation, and construction concept of operations are discussed.
lunar infrastructure↗
Design of an unmanned lunar cargo lander that reconfigures into a shelter for a habitation module or disassembles into parts useful to a permanent manned lunar base
NASA plans to establish a permanent manned lunar base by the first decade of the twenty-first century. It is extremely expensive to transport material from earth to the moon. Therefore, expense would be reduced if the vehicle that lands cargo on the moon could itself meet some of the material needs of establishing the lunar base. The design of a multi-functional lander that is entirely useful to the base after landing is described. Alternate designs of the overall lander configuration and possible uses of the lander and its components after landing are contained. The design solution is a lander employing the Saddlebagged Fuel Tank Configuration. After landing, its structure will be converted into a habitation module shelter that supports a protective layer of regolith. The fuel tanks will be cleaned and used as storage tanks for the lunar base. The engines and instrumentation will be saved as stock parts. Recommendations for further research and technology development to enhance future lander designs are given.
Davanay, Lisa↗
Apollo 2 Second Generation Lunar Exploration System Studies CFY 1963
The Apollo II Second Generation Lunar Exploration System includes the direct landing spacecraft which consists of cargo command module, service module, and landing module. The landing module is also capable of being used as the Lunar Landing Vehicle (LLV) for landing unmanned cargos consisting of shelter modules such as the Lunar Occupancy Payload and other cargo in support of lunar surface operations. High energy cryogenic propellants are utilized to permit direct landing, manned, or logistic missions with use of a single Saturn V class booster. In last year's studies, the LLV was configured for maximum payload and with consideration for the direct three-man landing and return mission. Light weight and low vehicle height above the lunar surface at touchdown were major objectives. Logistic cargos of more than 27,000 pounds landed on the Moon were achieved within the single Saturn V boost capability. For the manned mission, the lunar take-off weight was determined to be 28,000 pounds ready for the return-to-Earth portion of the mission. The command module utilized was an advanced light-weight design weighing 10,000 pounds including supporting subsystems. Cryogenic oxygen/hydrogen propulsion was again used for maximum propulsion efficiency. Study of the Lunar Occupancy Payload was also accomplished last year. This module was configured to serve as an early lunar shelter or outpost station or as a basic module of an integrated base module complex. Single and dual compartment versions, as well as special mission versions, were studied.
Matzenaur, J. O.↗
Protective clothing textile research for space activities in the 1980's
Textile and clothing specifications for space activities are discussed, emphasizing a chronological and utilitarian role. New fabrication techniques led to the Mercury Space Suit, a constant-wear hybrid of the omni-environmental full pressure suit used by high-flying pilots of the 1950s. The Gemini program (1964-1966) provided the first specifically designed protective clothing assembly for both intra- and extravehicular operations. The G4C, used for EV (extravehicular) activities, protected the astronaut against solar radiation, heat loss, and meteoroid penetration. The clothing for the Apollo program (1968-1975) mirrored a greater concern for fire safety with Durette (a halogenated polyamide) and PBI (polybenzimadazole) widely used for intravehicular garments. With the advent of the Shuttle program, cabin pressure and composition were changed from 6 psi, 100% oxygen to 9-14 psi, 23.4% oxygen, 76.6% N2. As a result, 'off-the-shelf' materials were used without compromising fire safety. Reusability was stressed, as textile costs and durability were now important selection criteria noting that existing textile materials will probably be adequate for the next 20 years of space operations and research. A portable lunar survival shelter made of textiles is being developed; and a preliminary design for an EV 'tunnel suit system' (an access tunnel and homoform work station) is already in existence.
Radnofsky, M. I.↗
Selection, Production, and Properties of Regolith Polymer Composites for Lunar Construction
NASA’s Artemis Program seeks to establish a long-term presence on the Moon to enable scientific exploration and expand the cis-lunar economy by utilizing lunar resources through public-private and international partnerships. Over the next decades, a lunar spaceport will need to be established to provide the services and facilities that are necessary to achieve this goal. Robotic construction technologies using in-situ materials must be developed to build up enabling infrastructure such as launch/landing pads, blast protection, power/communications infrastructure, improved roads, improved operational surfaces, and radiation protection shelters. Kennedy Space Center’s Granular Mechanics and Regolith Operations laboratory at Swamp Works has partnered with SpaceFactory and LERA Consulting Structural Engineers to develop the architectural and structural design of an unpressurized lunar shelter. The shelter, called Lunar Infrastructure Asset (LINA), is designed to support 2.3 m of regolith overburden to protect astronauts and surface assets from radiation, meteoroid impact, thermal gradients/cycling, and to withstand moonquakes. LINA’s structural design criteria and the resulting structure design are detailed in separate papers. A Fused Filament Fabrication (FFF) construction process using regolith polymer composites has been developed and is detailed in a separate publication. This paper presents material formulations and selection rationale for each of the composite components that were examined. Formulations include 70:30, 80:20, and 85:15 wt.% mixture ratios of lunar mare simulant Black Point-1 (BP-1): Polylactic Acid (PLA), 80:20 Lunar Highlands Simulant-1 (LHS-1): PLA and an 80:20 BP-1: PLA formulation with a flow enhancer additive. Test samples were printed in simulated lunar dirty thermal vacuum conditions (-190 °C, 10-3 torr). A series of tests were performed on each formulation to characterize the achieved mixture ratio, mechanical strength properties, off-gassing products during vacuum printing, and porosity and density of printed products. The LHS-1: PLA formulation yielded an advantageous combination of properties and was used in a final test that additively constructed a sub-scaled LINA on regolith simulant in dirty vacuum conditions. The materials and construction process presented in this paper are considered to be at Technology Readiness Level (TRL) 5 with additional testing necessary to characterize long term lunar environmental exposure effects.
lunar infrastructure↗
Relevant Environment Additive Construction Technology (REACT)
Advancing the TRL of technologies developed during the NASA 3D Printed Habitat Centennial Challenge. Focused on the design and construction of a lunar unpressurized radiation protection shelter called LINA.
lunar infrastructure↗
A survey of surface structures and subsurface developments for lunar bases
Concepts proposed for lunar-base structures and shelters include those fabricated on earth, fabricated locally using lunar materials, and developed from subsurface features. Early bases may rely on evolutionary growth using Space Station modules and nodes covered with regolith for protection against thermal and radiative stresses. Expandable/inflatable shelters used alone on the surface or in conjunction with subselene (beneath the lunar surface) features and spent portions of the Space Shuttle's fuel tanks offer early alternatives. More mature lunar bases may need larger volumes provided by erectable buildings, hybrid inflatable/rigid spheres, modular concrete buildings using locally derived cement, or larger subselene developments.
Hypes, Warren D.↗
A One-Piece Lunar Regolith Bag Garage Prototype
Shelter structures on the moon, even in early phases of exploration, should incorporate lunar materials as much as possible. This Technical Memorandum details the design and construction of a prototype for a one-piece regolith bag unpressurized garage concept and a materials testing program to investigate six candidate fabrics to learn how they might perform in the lunar environment. The conceptualization was that a lightweight fabric form be launched from Earth and landed on the lunar surface to be robotically filled with raw lunar regolith. Regolith bag fabric candidates included: Vectran(TM), Nextel(TM), Gore PTFE Fabric(TM), Zylon(TM), Twaron(TM), and Nomex(TM). Tensile (including post radiation exposure), fold, abrasion, and hypervelocity impact testing were performed under ambient conditions, and also performed under cold and elevated temperatures. In some cases, Johnson Space Center lunar simulant (JSC-1) was used in conjunction with testing. A series of preliminary structures was constructed during final prototype design based on the principles of the classic masonry arch. The prototype was constructed of Kevlar(TM) and filled with vermiculite. The structure is free-standing, but has not yet been load tested. Future plans would be to construct higher fidelity prototypes and to conduct appropriate tests of the structure.
Smithers, G. A.↗
Protecting Crew and Surface Systems with a Long-Duration Lunar Safe Haven
NASA’s Artemis program will send astronauts to the lunar surface for extended mission durations throughout the 2030s, with a focus on sustainability and extensibility for Mars exploration, as described in NASA’s “Artemis Plan”. However, NASA must place more emphasis on protecting both the crew and the exploration surface systems if they hope to achieve long-duration sustainability on the lunar surface. It is now reasonably achievable with excavation, construction, and autonomy technologies to achieve a significant level of protection that architectures have been unable to achieve to date. The Lunar Safe Haven (LSH) was proposed to protect astronauts, electronics, and other surface exploration systems from the hazards of the lunar environment, including radiation, micrometeoroid strikes, lunar dust, thermal vacuum, etc. During the study, Level Zero Requirements were developed for the LSH, and a decision analysis framework was baselined to evaluate concepts. The LSH Study also performed a comprehensive trade study, during which it identified numerous alternatives for establishing and maintaining a safe haven shelter on the lunar surface. This paper reviews the products developed during the study and presents the final recommendations.
radiation shielding↗
Lunar stay time extension module
Stay time extension module shelter structure to support 2 men for 8 days on lunar surface
SPACECREW↗
A One-Piece Lunar Regolith-Bag Garage Prototype
Shelter structures on the moon, even in early phases of exploration, should incorporate lunar materials as much as possible. We designed and constructed a prototype for a one-piece regolith-bag unpressurized garage concept, and, in parallel, we conducted a materials testing program to investigate six candidate fabrics to learn how they might perform in the lunar environment. In our concept, a lightweight fabric form is launched from Earth to be landed on the lunar surface and robotically filled with raw lunar regolith. In the materials testing program, regolith-bag fabric candidates included: VectranTM, NextelTM, Gore PTFE FabricTM, ZylonTM TwaronTM and NomexTM. Tensile (including post radiation exposure), fold, abrasion, and hypervelocity impact testing were performed under ambient conditions, and, within our current means, we also performed these tests under cold and elevated temperatures. In some cases, lunar simulant (JSC-1) was used in conjunction with testing. Our ambition is to continuously refine our testing to reach lunar environmental conditions to the extent possible. A series of preliminary structures were constructed during design of the final prototype. Design is based on the principles of the classic masonry arch. The prototype was constructed of KevlarTM and filled with vermiculite (fairly close to the weight of lunar regolith on the moon). The structure is free-standing, but has not yet been load tested. Our plan for the future would be to construct higher fidelty mockups with each iteration, and to conduct appropriate tests of the structure.
Smithers, Gweneth A.↗
A One-Piece Lunar Regolith-Bag Garage Prototype
Shelter structures on the moon, even in early phases of exploration, should incorporate lunar materials as much as possible. We designed and constructed a prototype for a one-piece regolith-bag unpressurized garage concept, and, in parallel, we conducted a materials testing program to investigate six candidate fabrics to learn how they might perform in the lunar environment. In our concept, a lightweight fabric form is launched from Earth to be landed on the lunar surface and robotically filled with raw lunar regolith. In the materials testing program, regolith-bag fabric candidates included: Vectran(TM), Nextel(TM), Gore PTFE Fabric(TM), Zylon(TM), Twaron(TM), and Nomex(TM). Tensile (including post radiation exposure), fold, abrasion, and hypervelocity impact testing were performed under ambient conditions, and, within our current means, we also performed these tests under cold and elevated temperatures. In some cases, lunar simulant (JSC-1) was used in conjunction with testing. Our ambition is to continuously refine our testing to reach lunar environmental conditions to the extent possible. A series of preliminary structures were constructed during design of the final prototype. Design is based on the principles of the classic masonry arch. The prototype was constructed of Kevlar(TM) and filled with vermiculite (fairly close to the weight of lunar regolith on the moon). The structure is free-standing, but has not yet been load tested. Our plan for the future would be to construct higher fidelity mockups with each iteration, and to conduct appropriate tests of the structure.
Smithers, Gweneth A.↗
Lunar lava tube radiation safety analysis
For many years it has been suggested that lava tubes on the Moon could provide an ideal location for a manned lunar base, by providing shelter from various natural hazards, such as cosmic radiation, meteorites, micrometeoroids, and impact crater ejecta, and also providing a natural environmental control, with a nearly constant temperature, unlike that of the lunar surface showing extreme variation in its diurnal cycle. An analysis of radiation safety issues on lunar lava tubes has been performed by considering radiation from galactic cosmic rays (GCR) and Solar Particle Events (SPE) interacting with the lunar surface, modeled as a regolith layer and rock. The chemical composition has been chosen as typical of the lunar regions where the largest number of lava tube candidates are found. Particles have been transported all through the regolith and the rock, and received particles flux and doses have been calculated. The radiation safety of lunar lava tubes environments has been demonstrated.
Non-programmatic↗
Moon to Mars Planetary Autonomous Construction Technology (MMPACT) Lunar Surface Construction Activity at NASA Marshall Space Flight Center
Introduction: The goal of the Moon to Mars Planetary Autonomous Construction Technology (MMPACT) Project at NASA Marshall Space Flight Center (MSFC) is to develop, deliver, and demonstrate on-demand capabilities to protect astronauts and create infrastructure elements on the lunar surface via construction of landing pads, habitats, shelters, roadways, berms, and blast shields using lunar regolith-based materials. MSFC has strong collaborations with industry, academia, and other NASA Centers to accomplish this goal. The MMPACT project consists of three elements. The first focuses on the development of an autonomous construction system. The second focuses on construction feedstock materials development. The third element focuses on the development of a microwave sintering construction capability. The team plans to demonstrate construction on a small Commercial Lunar Payload Services (CLPS) lander in the 2025 timeframe, with a future goal of constructing a subscale landing pad in 2028-2029.The MMPACT project is funded through the Lunar Surface Innovation Initiative, which is part of the Space Technology Mission Directorate. Technology Development: The MMPACT team will evaluate multiple autonomous construction and microwave construction technologies, materials, and construction element forms. Selected technologies will be matured; processes and operations will be defined for the two flight missions. Evaluations of materials, as well as the technology itself, will be demonstrated in simulated lunar environments as part of the technology maturation process. The team is keenly aware of the properties of the lunar environment. Its temperature swings, negligible exosphere, and unprepared site foundations factor into the materials for both construction and hardware, the concept of operations, and the technology’s interdependencies. Materials: The team is looking at materials that can be produced from in-situ resources in an effort to make lunar construction cost-effective. The particular focus of the materials team is cementitious materials, metals, and sintered and melted regolith. These materials will be studied for tensile, compressive, and flexural strength. They will also be tested for their ability to handle thermal swings and vacuum. They will be fully characterized using various microscopy techniques to examine micro-structures, chemistry, and crystal formation. Interdependencies: There are many interdependencies that MMPACT has already identified. These include: •Excavation interface •Regolith feedstock beneficiation •Regolith feedstock storage and provision •Requirements for structures •Site-to-site mobility systems •Availability of lunar simulant •Lander off-loading capabilities •Navigation systems •Power •Regolith composition and mineralogy •Lander specifications •Communication protocols Technology developments in these additional areas would be beneficial to MMPACT.
Moon to Mars Planetary Autonomous Construction Tec↗
NASA’s Moon-to-Mars Planetary Autonomous Construction Technology Project: Overview and Status
NASA plans to land the first woman and next man on the Moon by 2025 through the initial Artemis missions. NASA and its international partners plan to establish a sustainable long-term presence on the lunar surface and build up infrastructure in the subsequent Artemis missions. The Lunar Surface Innovation Initiative (LSII), within NASA’s Space Technology Mission Directorate, aims to spur the creation of novel technologies needed for lunar surface exploration and accelerate the technology readiness of key systems and components. The primary thrust areas of LSII include sustainable power; dust mitigation; in-situ resource utilization; surface excavation, construction, and outfitting; and extreme access/extreme environments. The Moon-to-Mars Planetary Autonomous Construction Technology (MMPACT) projectwas initiated to address the lunar surface construction thrust area of LSII. The goal of the MMPACT project is to develop, deliver, and demonstrate on-demand capabilities to protect astronauts and create infrastructure on the lunar surface via construction of landing pads, habitats, shelters, roadways, berms and blast shields using lunar regolith-based materials. The MMPACT project is leveraging technology derived from NASA’s 3D Printed Mars Habitat Challenge along with contributions from other Government agencies, and multiple partners within industry and academia. The MMPACT project is comprised of three interrelated elements, construction hardware and process development; feedstock materials development; and microwave structure construction capabilities. These elements are working together to address the multiple challenges of infrastructure construction on the surface of the Moon including increased autonomy of operations, hardware operation and manufacturing under lunar environmental conditions, long-duration operation of mechanisms and parts, scale of construction activities, and material and construction requirements and standards. This presentation will summarize the status of development activities in each of the three elements, including testing of the various candidate materials, preliminary design concepts for future lunar infrastructure elements, and the vision for future technology demonstrations on the lunar surface. These demonstrations, targeting the mid-to-late 2020’s, are expected to enable landing pad construction and habitat construction resulting in commercial capabilities early in the next decade.
lunar infrastructure↗