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All sourcesNASA NTRSDOE OSTI
NASA NTRSDate not supplied

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↗
NASA NTRSDate not supplied

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↗
NASA NTRSDate not supplied

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 discoveries and utilization of lunar resources through public-private partnerships. Over the next decades, a lunar spaceport enabling regular transportation from and to Earth 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 towers, improved trafficability pathways and radiation protection shelters. Kennedy Space Center’s Granular Mechanics and Regolith Operations laboratory at Swamp Works has partnered with AI SpaceFactory to develop the architectural and structural design of an unpressurized shelter. The shelter, called Lina, is designed to protect astronauts and surface assets from radiation, meteoroid impact, moon quakes and thermal gradients. 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. This paper presents the material formulations and selection rationale for each of the composite components. 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 (LHS-1): PLA and an 80:20 BP-1:PLA formulation with a processing aid/compatibilizer additive. Test samples were printed in simulated lunar dirty thermal vacuum conditions (~-180 °C, ~10 -3 torr). The test environment evolved throughout the duration of the print process. A series of tests were performed to characterize the mixture ratios achieved for each formulation, the off-gassing products during vacuum printing, the strength properties, and porosity 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.

lunar infrastructure↗
NASA NTRS2005

Construction and Resource Utilization Explorer: Regolith Characterization Using a Modular Instrument Suite and Analysis Tools

The Construction Resource Utilization Explorer (CRUX) is a technology maturation project for the U.S. National Aeronautics and Space Administration to provide enabling technology for lunar and planetary surface operations (LPSO). The CRUX will have 10 instruments, a data handling function (Mapper - with features of data subscription, fusion, interpretation, and publication through geographical information system [GIs] displays), and a decision support system DSS) to provide information needed to plan and conduct LPSO. Six CRUX instruments are associated with an instrumented drill to directly measure regolith properties (thermal, electrical, mechanical, and textural) and to determine the presence of water and other hydrogen sources to a depth of about 2 m (Prospector). CRUX surface and geophysical instruments (Surveyor) are designed to determine the presence of hydrogen, delineate near subsurface properties, stratigraphy, and buried objects over a broad area through the use of neutron and seismic probes, and ground penetrating radar. Techniques to receive data from existing space qualified stereo pair cameras to determine surface topography will also be part of the CRUX. The Mapper will ingest information from CRUX instruments and other lunar and planetary data sources, and provide data handling and display features for DSS output. CRUX operation will be semi-autonomous and near real-time to allow its use for either planning or operations purposes.

Moon↗
NASA NTRSDate not supplied

Moon-to-Mars Planetary Construction Technology (MMPACT) Scoop, Tamp, Filter (STF) Sub-System

NASA’s Space Technology Mission Directorate “champions technologies needed to live on and explore the Moon” [1]. This includes capabilities that capitalize on existing lunar resources and carry out surface manufacturing and construction activities. The goal of the Moon-to-Mars Planetary Construction Technology (MMPACT) Project is to mature these two capabilities. The primary resource on the Moon and the primary feedstock for manufacturing and construction is regolith. In the past, astronauts launched, landed, and lived in a spacecraft. NASA envisions a future where we make living spaces on the lunar surface instead. The innovative technologies required for lunar surface construction may be something never seen before, or they may be adaptations of existing technologies. This paper summarizes recent efforts to develop and test a scoop, tamp and filter (STF) sub-system to prepare and deposit lunar regolith for a laser-based vitreous material transformation system being developed under a NASA contract by ICON, inc., which is hoped to eventually be used for automated additive construction with indigenous regolith on the Moon.

Moon↗
NASA NTRS2024

Material Inspectability Assessment Related to Lunar Construction Technology Development

For the building of lunar structures on the Moon using lunar regolith-based construction materials, ensuring their structural integrity and employing methods optimal for such tasks is crucial. In this technical memorandum (TM) the detectability of simulated void defects in a cementitious-based lunar construction material is compared between different nondestructive evaluation (NDE) methods, especially methods which have potential to be developed into space qualified instruments. Primarily, simulated voids, introduced during fabrication as foam spheres, were used for this evaluation. Furthermore, smaller, unintended void defects were used to assess the detectability. The results highlights trade-offs between the NDE methods in terms of detection limit, correct size indication, penetration depth, and potential for reduction in size, weight, and power (SWaP).

Nondestructive Evaluation↗
NASA NTRSDate not supplied

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↗
NASA NTRS2023

Moon-to-Mars Planetary Autonomous Construction Technology: MMPACT Material Screening

NASA’s Space Technology Mission Directorate “champions technologies needed to live on and explore the Moon” [1]. This includes capabilities that capitalize on existing lunar resources and carry out surface manufacturing and construction activities. The goal of the Moon-to-Mars Planetary Construction Technology (MMPACT) Project is to mature these two capabilities. The primary resource on the Moon and the primary feedstock for manufacturing and construction is regolith. In the past, astronauts launched, landed, and lived in a spacecraft. NASA envisions a future where we make living spaces on the lunar surface instead. The innovative technologies required for lunar surface construction may be something never seen before, or they may be adaptations of existing technologies. MMPACT must screen for the most feasible technologies with the earliest potential technology insertions given the ambitious goals of the Artemis campaign. This poster summarizes recent efforts to discover and document mechanical and thermal capabilities of various technologies: a laser-based vitreous material transformation from Texas-based ICON, a molten extrusion process from ICON, a mortar from MSFC, a mortar from an MSFC-Louisiana State University partnership, and a geopolymer from a MSFC-Pennsylvania State University partnership. Other testing and development activities are documented as well. [1] https://www.nasa.gov/directorates/spacetech/Lunar_Surface_Innovation_Initiative

In-situ Resource Utilization↗
NASA NTRSDate not supplied

Advanced Materials Testing for Lunar Landing & Launch Pad Construction

Five candidate lunar landing and launch pad candidate materials were evaluated in relevant Oxygen/Methane rocket engine plume environment exposure tests. The performance trends were modeled, observed, measured (to the extent possible), and testing results were evaluated. A total of fifteen high temperature plume tests were performed in two test campaigns: five in December 2020 and ten in March 2021. The results indicate that several of the selected materials are promising for future consideration in designing and building lunar landing and launch pads, although further development work is needed for all of them.

landing pad↗