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An Integrated Exploration Strategy

Many new scientific findings in planetary science (potential life in a Mars meteorite, possible frozen water at the Lunar Poles, permanently lit region at the lunar south pole, recent water flow on Mars) provide a compelling case for humans to once again leave low earth orbit and explore. Robotic missions are capable of conducting science, but only humans can explore and discover. The challenge is to build an affordable exploration program. This can be done by aggressively evolving our current systems, developing high payoff technologies, leveraging off commercial and other agencies' programs, and developing a set of core capabilities to be used to explore a variety of destinations. NASA has a Strategic Roadmap based on detailed mission studies to develop these core technologies and capabilities to allow human space exploration. Advances in human support, launch vehicle. improvements, development of in-space transportation systems, efficient power generation and distribution, and In-Situ Resource Utilization are all required to meet the exploration challenge. The groundwork today will provide the technology and tools needed to conduct safe, affordable, and efficient exploration to the moon, asteroids, deep space observatories and Mars.

Conley, Mike↗

Investigation of Lunar-Inspired Geopolymer Concrete Formulations Mixed and Cured in Microgravity on the International Space Station (ISS)

The research outlined in this presentation investigates the use of various lunar regolith simulants in geopolymer lunar concrete mixes mixed and cured on the International Space Station (ISS). The motivation for this work is to study the effects of gravity on the microstructure of alkali-activated materials cured with heat, and to develop materials for the construction of long-term infrastructure on the lunar surface with in-situ resource utilization (ISRU). ISRU for construction materials reduces the cost and mass of payloads related to lunar construction. The advantage of geopolymer concrete as opposed to traditional portland cement concrete is that water acts as a medium for the polymerization reaction and leaves the system throughout the process, reducing its demand. Twelve samples of lunar regolith simulant and a solution composed of sodium hydroxide and sodium silicate were sent to the ISS. The three simulants were OPRH2N, OPRL2N, and JSC-1AF, using only particles less than 53 µm in diameter to increase reactivity of the simulant. Simulant to solution ratios were determined by workability while mixing. The simulant and solution were sealed Burst Pouches® along with 2 other sealed bags to prevent material from leaking. Crew member F-14 conducted testing on the ISS by introducing the solution to the simulant in the Burst Pouch®, mixing the sample with a spatula, and then clamping the specimen in the fresh state to prevent flow inside the Burst Pouch®. These specimens were then put in a thermos heated to 80C via sealed drinking water bags to cure for 24 hours with a temperature logger. The cured specimens remained in microgravity for at least 28 days and were returned from the ISS in February 2025. The specimens were then brought to the NASA Marshall Space Flight Center (MSFC) to analyze. Material characterization consisted of conducting Micro-CT tests of entire samples in their sealed apparatus to a resolution of 25µm. 2D image slices were saved in each orthogonal direction of each specimen at a 0.03 mm step size from the 3D model to conduct analytical porosity calculations. Representative samples from each specimen were sampled to perform helium gas pycnometery and were then mounted in resin for SEM imaging, EDS, and nanoindentation. Porosity was analyzed analytically using micromechanics modelling with the assistance of the NASA Multiscale Analysis Tool (NASMAT), as well as the NASA Advanced Supercomputing (NAS) servers (V. Saseendran & N. Yamamoto, 2024). Density was measured using helium gas pycnometery and was then compared to the theoretical density for experimental porosity calculation. Due to the samples’ non-uniform shape being cured in a pouch, traditional compression and tensile strength testing could not be performed. Nanoindentation was conducted at Clarkson University to determine the microhardness and reduced modulus of elasticity. Results from flight samples can be compared to ground samples currently in DLR’s possession to determine the effect on microstructure from being mixed and cured in microgravity. This study gives further insight and understanding of geopolymer lunar concrete and its viability as a lunar construction material with ISRU.

Adam Johnson↗

Extrusion-based Additive Manufacturing of Regolith-Filled Shape Memory Vitrimer Composite for Lunar Construction

The National Aeronautics and Space Administration (NASA) is visiting the moon again. This time, the objective is to explore establishing a permanent lunar base. To achieve both longterm human habitation on the moon and future deep space travel, it is crucial to make the most of the in-situ resources and build autonomous systems on the moon to support the construction of a lunar habitat. NASA’s In-situ Resource Utilization (ISRU) program aims to minimize the need to ship heavy prefabricated structures, reducing cost and enhancing sustainability. Here, we developed an economical extrusion method for printing lunar regolith-based composites using shape memory vitrimer as a binder. A rheological study is conducted to determine the extrudability of the composite with different regolith weight percentages. Several characterizations were conducted on the composites. The as-printed composites exhibited compressive and flexural strengths of 73.32 MPa and 156.59 MPa, respectively, and good impact tolerance. The composite maintained 57.92% of its mechanical properties even after the second crack healing cycle. The composites also exhibit shape fixity ratio of 90.02% and shape recovery ratio of 83.46%. The simple synthesis method, sustainability, and good thermomechanical properties make the 3D printed composite an ideal material for lunar construction applications.

Kingsley Yeboah Gyabaah↗

In-Situ Production of Solar Power Systems for Exploration

Current proposals for developing an extended human presence, beyond space stations, on the Moon and Mars increasingly consider the processing of non-terrestrial materials essential for keeping the Earth launch burden reasonable. Utilization of in-situ resources for construction of lunar and Mars bases will initially require assessment of resource availability followed by the development of economically acceptable and technically feasible extractive processes. In regard to materials processing and fabrication the lower gravity level on the Moon (0.125 g) and Mars (0.367 g) will dramatically change the presently accepted hierarchy of materials in terms of specific properties, a factor which must be understood and exploited. Furthermore, significant changes are expected in the behavior of liquid materials during processing. In casting, for example, mold filling and associated solidification processes have to be reevaluated. Finally microstructural development and therefore material properties, presently being documented through on-going research in microgravity science and applications, needs to be understood and scaled to the reduced gravity environments. One of the most important elements of a human planetary base is power production. Lunar samples and geophysical measurements returned by the Apollo missions provide detailed data on the composition and physical characteristics of the lunar materials and environment. Based on this knowledge and extrapolations of terrestrial industrial experience it is clear that several types of solar-to-electric converters can be manufactured on the Moon. It is conceivable that well over 90% of a solar-to- electric power system could be made from lunar materials. Production and utilization of photovoltaic devices for solar energy production on Earth is primarily driven by the market economy. On Earth a production plant for photovoltaic devices is intimately linked to the planets massive industrial base. A selection of off the shelf refined materials are available as well as cheap fast transportation on demand. The processes takes place (except for the few seconds reprieve in shot towers etc.) under one gravity, with solar radiation significantly modulated by weather, and under conditions where one atmosphere is free and high vacuum is cumbersome and expensive. Off Earth, on lunar or Mars bases, the cost of photovoltaic power is driven by transport costs - Earth launch, deep space transport, landing on the planetary surface. Thus there is a premium for processes that are materials self-sufficient or for closed loop in-situ processes. The lack of differentiated ores on the Moon, and lack of explored minerals on Mars and interplanetary space give a premium to universal/non-ore-specific mineral extractive processes. Initially a semiconductor/photovoltaic production facility will build on no conveniently located industrial base, further increasing the premium on closed loop self sufficient processes.

Curreri, Peter A.↗

Technologies of ISRU/ISMU

The objectives of this paper are twofold. One is to unambiguously identify those in situ resource utilization (ISRU) in-situ materials utilization (ISMU) technologies that have matured past the stage of speculation, or uncertainty, and to present as much quantitative data as possible from working hardware. The second objective is to bring to the attention of the concerned authorities the important fact that many of the technologies are sufficiently advanced today to be seriously considered in the planning of space missions. The paper gives a brief overview of ISRU/ISMU from the literature. Next, results obtained from a well-planned set of research activities to promote ISRU/ISMU are quoted. These include some general technologies such as cryo coolers, power modules, and information systems followed by some very specific technologies such as oxygen production on the moon and Mars.

Ramohalli, Kumar↗

Vehicle and Mission Design Options for the Human Exploration of Mars/Phobos Using "Bimodal" NTR and LANTR Propulsion

The nuclear thermal rocket (NTR) is one of the leading propulsion options for future human missions to Mars because of its high specific impulse (Isp-850-1000 s) capability and its attractive engine thrust-to-weight ratio (approximately equal 3-10). To stay within the available mass and payload volume limits of a "Magnum" heavy lift vehicle, a high performance propulsion system is required for trans-Mars injection (TMI). An expendable TMI stage, powered by three 15 thousand pounds force (klbf) NTR engines is currently under consideration by NASA for its Design Reference Mission (DRM). However, because of the miniscule burnup of enriched uranium-235 during the Earth departure phase (approximately 10 grams out of 33 kilograms in each NTR core), disposal of the TMI stage and its engines after a single use is a costly and inefficient use of this high performance stage. By reconfiguring the engines for both propulsive thrust and modest power generation (referred to as "bimodal" operation), a robust, multiple burn, "power-rich" stage with propulsive Mars capture and reuse capability is possible, A family of modular "bimodal" NTR (BNTR) vehicles are described which utilize a common "core" stage powered by three 15 klbf BNTRs that produce 50 kWe of total electrical power for crew life support, an active refrigeration / reliquification system for long term, "zero-boiloff" liquid hydrogen (LH 2 ) storage, and high data rate communications. An innovative, spine-like "saddle truss" design connects the core stage and payload element and is open underneath to allow supplemental "in-line" propellant tanks and contingency crew consumables to be easily jettisoned to improve vehicle performance. A "modified" DRM using BNTR transfer vehicles requires fewer transportation system elements, reduces IMLEO and mission risk, and simplifies space operations. By taking the next logical step--use of the BNTR for propulsive capture of all payload elements into Mars orbit--the power available in Mars orbit grows to 150 kWe compared to 30 kWe for the DRM. Propulsive capture also eliminates the complex, higher risk aerobraking and capture maneuver which is replaced by a simpler reentry using a standardized, lower mass "aerodescent" shell. The attractiveness of the "all BNTR" option is further increased by the substitution of the lightweight, inflatable "TransHab" module in place of the heavier, hard-shell hab module. Use of TransHab introduces the potential for propulsive recovery and reuse of the BNTR/ERV. It also allows the crew to travel to and from Mar on the same BNTR transfer vehicle thereby cutting the duration of the ERV mission in half--from approximately 4.7 to 2.5 years. Finally, for difficult Mars options, such as Phobos rendezvous and sample return missions, volume (not mass) constraints limit the performance of the "all LH 2 " BNTR stage. The use of "LOX-augmented" NTR (LANTR) engines, operating at a modest oxygen-to-hydrogen mixutre ratio (MR) of 0.5, helps to increase "bulk" propellant density and total thrust during the TMI burn. On all subsequent burns, the bimodal LANTR engines operate on LH 2 only (MR=0) to maximize vehicle performance while staying within the lift capability of two Magnum launches.

Nuclear thermal rocket↗

Polymer/Regolith Composites for In-Space Manufacturing on the Moon and Mars

In-Space Manufacturing (ISM) is vital to supporting a sustained human presence on the Moon or Mars. With payload launch prices ranging from $4,000 to more than $1 million per kg, reducing payload mass is of critical interest. Using in-situ resources for ISM is particularly attractive as it allows for a system of Earth-independent manufacturing for the Lunar surface, reducing the initial payload mass that is required for current ISM systems that rely on terrestrially synthesized materials. This talk presents new composite materials made from Lunar and Martian regolith and Poly(3-hydroxybutyrate) (PHB), a thermoplastic that offers the ability to be biosynthesized in space using various in-situ resources like organic waste or atmospheric CO2 as feedstock. The addition of regolith provides a route to creating materials with a diverse set of properties which will be discussed. The development of these materials represents the first step in creating a system of closed-loop ISM, which is critical to establishing a lasting human presence in space.

In-situ resource utilization↗

Autonomous space processor for orbital debris removal and flame augmentation additives in scramjets for the National Aerospace Plane

This is a brief description of the USRA-sponsored design project at the University of Arizona. Approximately eighty-percent of this effort was spent pursuing a novel engineering concept for the in-situ processing of orbital debris utilizing resources available in low Earth orbit (LEO); the other twenty-percent was devoted to discovering innovative additives for the anchoring of supersonic combustion zones that find direct use in the Aerospace Plane that is expected to use scramjets. The seriousness of the orbital debris problem is briefly described. Available 'solutions' are outlined from the literature. The engineering design is briefly mentioned, with an emphasis on the positive aspects of the space environment that should be used in an economical approach. The aspects of operating in microgravity, vacuum, and in utilizing solar energy are mentioned. A quantitative computer animation was developed to provide design data. Three specific dead spacecraft were identified for an initial cleanup mission. The design concept, which includes a solar processor, remote arm manipulators, and the gradual processing of the debris, is also described. This is followed by a description of hardware construction. Operation and actual processing of simulated debris parts (aluminum, for now) are demonstrated in the NASP task, construction of the new design for measuring the radiation from the key free radicals (as enhanced by the additives) is described. Immediate (1988) and long-range (through 1992) future plans are shown to clearly indicate the full engineering design strategy in the light of the national space program thrusts.

Source record↗

Oxygen Generator System Mars In-Situ Propellant Production Precursor Flight

The 2001 Lander to Mars will carry the first ever In situ Resource Utilization (ISRU) payload to Mars. This payload, the Mars In-situ Propellant production Precursor (MIP), will demonstrate a variety of technologies that will be required for future ISRU Mars indigenous material processing plant designs. One of those technologies is that of extracting oxygen from the predominantly carbon dioxide atmosphere of Mars, a prerequisite for future sample return and human missions to Mars. The Oxygen Generator Subsystem (OGS) portion of the MIP will demonstrate this and is the focus of this paper. The primary objective of the OGS is to demonstrate the production of oxygen from Mars atmospheric gases. Secondary objectives are to measure the performance and reliability of oxygen generation hardware in actual mission environments over an extended time. Major constraints on the OGS design came from several sources. The Lander provides power to the system from solar power that is harnessed by photovoltaic arrays. This limited OGS to daytime only operations (six to eight hours) and a maximum power of 15W. The reliance on solar power necessitated thermal cycling of the OGS between Mars ambient and OGS operating temperatures. The Lander also limited the total mass of the MIP payload to 7.5 kg with a correspondingly small volume, and the OGS was one of six experiments in the MIP Mass and volume were to be minimized. Another constraint was cost. Mission funding, as always, was tight. Cost was to be minimized. In short the OGS design had to be low power (<15 Watts), low mass (1 kg), low volume, low cost, and be capable of cyclical operations for an extended stay on Mars. After extensive research, a zirconia based solid oxide electrolyzer design was selected.

Sridhar, K. R.↗

Proposed lunar missions

Three lunar missions are proposed: a 65 kg Artemis payload with an in-situ materials utilization (ISMU) pilot plant; a 65 kg Artemis payload with a lunar resource prospector; and a 200 kg Artemis payload with an integrated oxygen production plant. All material is presented in viewgraph format.

Schooley, Larry↗

Economical in-situ processing for orbital debris removal

This paper proposes and develops the first description of a concept for the removal of large pieces of orbital debris. After a brief discussion of the growing importance of the general problem of orbital debris, the idea of utilizing local resources for clearing the debris is introduced. A description of the initial terrestrially working hardware and future projections for this Autonomous Space Processor for Orbital Debris concludes this paper.

Ramohalli, Kumar↗

Smart Optical RAM for Fast Information Management and Analysis

Statement of Problem Instruments for high speed and high capacity in-situ data identification, classification and storage capabilities are needed by NASA for the information management and analysis of extremely large volume of data sets in future space exploration, space habitation and utilization, in addition to the various missions to planet-earth programs. Parameters such as communication delays, limited resources, and inaccessibility of human manipulation require more intelligent, compact, low power, and light weight information management and data storage techniques. New and innovative algorithms and architecture using photonics will enable us to meet these challenges. The technology has applications for other government and public agencies.

Liu, Hua-Kuang↗

Structural Analysis of the QCM Aboard the ER-2

As a result of recent supersonic transport (SST) studies on the effect they may have on the atmosphere, several experiments have been proposed to capture and evaluate samples of the stratosphere where SST's travel. One means to achieve this is to utilize the quartz crystal microbalance (QCM) installed aboard the ER-2, formerly the U-2 reconnaissance aircraft. The QCM is a cascade impactor designed to perform in-situ, real-time measurements of aerosols and chemical vapors at an altitude of 60,000 - 70,000 feet. The ER-2 is primarily used by NASA for Earth resources to test new sensor systems before they are placed aboard satellites. One of the main reasons the ER-2 is used for this flight experiment is its capability to fly approximately twelve miles above sea level (can reach an altitude of 78,000 feet). Because the ER-2 operates at such a high altitude, it is of special interest to scientists interested in space exploration or supersonic aircraft. Some of the experiments are designed to extract data from the atmosphere around the ER-2. For the current flight experiment, the QCM is housed in a frame that is connected to an outer pod that is attached to the fuselage of the ER-2. Due to the location of the QCM within the housing frame and the location of the pod on the ER-2, the pod and its contents are subject to structural loads. In addition to structural loads, structural vibrations are also of importance because the QCM is a frequency induced instrument. Therefore, a structural analysis of the instrument within the frame is imperative to determine if resonance and/or undesirable deformations occur.

Jones, Phyllis D.↗

Structural Loading on the QCM/SAW Instrument Aboard the ER-2 Used for Atmospheric Testing

Several experiments have been proposed to capture and evaluate samples of the atmosphere where SST's travel. One means to achieve this is to utilize the quartz crystal microbalance (QCM) / surface acoustical wave (SAW) instrument installed aboard the ER-2, formerly the U-2 reconnaissance aircraft. The QCM is a cascade impactor designed to perform in-situ, real-time measurements of aerosols and chemical vapors at an altitude of 60,000-70,000 feet. The primary use of the ER-2 is by NASA for Earth resources to test new sensor systems before being placed aboard satellites. One of the main reasons the ER-2 is used for this flight experiment is its capability to fly approximately twelve miles above the sea level (can reach an altitude of 78,000 feet). Because the ER-2 operates at such a high altitude, it is of special interest to scientists interested in space exploration or supersonic aircraft. The purpose of some of the experiments is to extinct data from the atmosphere around the ER-2. For the current CSTEA flight experiment, the housing of the QCM is in a frame that connects to an outer pod that attaches to the fuselage of the ER-2. Due to the location of the QCM within the housing frame and the location of the pod on the ER-2, the pod and its contents are subject to structural loads. In addition to structural loads, structural vibrations are also of importance because the QCM output data is based on the determination of beat frequencies between a pair of oscillators (one coated, the second uncoated, according to the chemical reaction being monitored). A structural analysis of this system can indicate whether potential resonances may exist between the (higher) structural modal frequencies and the beat frequencies. In addition undesirable deformations may result due to maximum expected static or dynamic loads during typical flight conditions. If the deformations are excessive they may adversely affect the accuracy the instrumentation output.

Bainum, Peter M.↗

Intelligent neuroprocessors for in-situ launch vehicle propulsion systems health management

Efficacy of existing on-board propulsion systems health management systems (HMS) are severely impacted by computational limitations (e.g., low sampling rates); paradigmatic limitations (e.g., low-fidelity logic/parameter redlining only, false alarms due to noisy/corrupted sensor signatures, preprogrammed diagnostics only); and telemetry bandwidth limitations on space/ground interactions. Ultra-compact/light, adaptive neural networks with massively parallel, asynchronous, fast reconfigurable and fault-tolerant information processing properties have already demonstrated significant potential for inflight diagnostic analyses and resource allocation with reduced ground dependence. In particular, they can automatically exploit correlation effects across multiple sensor streams (plume analyzer, flow meters, vibration detectors, etc.) so as to detect anomaly signatures that cannot be determined from the exploitation of single sensor. Furthermore, neural networks have already demonstrated the potential for impacting real-time fault recovery in vehicle subsystems by adaptively regulating combustion mixture/power subsystems and optimizing resource utilization under degraded conditions. A class of high-performance neuroprocessors, developed at JPL, that have demonstrated potential for next-generation HMS for a family of space transportation vehicles envisioned for the next few decades, including HLLV, NLS, and space shuttle is presented. Of fundamental interest are intelligent neuroprocessors for real-time plume analysis, optimizing combustion mixture-ratio, and feedback to hydraulic, pneumatic control systems. This class includes concurrently asynchronous reprogrammable, nonvolatile, analog neural processors with high speed, high bandwidth electronic/optical I/O interfaced, with special emphasis on NASA's unique requirements in terms of performance, reliability, ultra-high density ultra-compactness, ultra-light weight devices, radiation hardened devices, power stringency, and long life terms.

Gulati, S.↗

Mars In-Situ Propellant Production Precursor (MIP) Flight Demonstration Project: Overview

Strategic planning for human missions of exploration to Mars has conclusively identified in-situ propellant production (ISPP) as an enabling technology. A team of scientists and engineers from NASA's Johnson Space Center, Jet Propulsion Laboratory, and Lewis Research Center is preparing the MARS ISPP Precursors (MIP) Flight Demonstration. The objectives of MIP are to characterize the performance of processes and hardware which are important to ISPP concepts and to demonstrate how these processes and hardware interact with the Mars environment. Operating this hardware in the actual Mars environment is extremely important due to both uncertainties in our knowledge of the Mars environment as well as because of conditions that cannot be adequately simulated on Earth. The MIP Flight Demonstration is a payload onboard the MARS SURVEYOR Lander and will be launched in April 2001. MIP will be the first hardware to utilize the indigenous resources of a planet or moon. Its successful operation will pave the way for future robotic and human missions to rely on propellants produced using Martian resources as feedstock.

Kaplan, D. I.↗

Mars In-Situ Propellant Production Precursor (MIP) Flight Demonstration Project: Overview

Strategic planning for human missions of exploration to Mars has conclusively identified in-situ propellant production (ISPP) as an enabling technology. A team of scientists and engineers from NASA's Johnson Space Center, Jet Propulsion Laboratory, and Lewis Research Center is preparing the MARS ISPP PRECURSOR (MIP) Flight Demonstration. The objectives of MIP are to characterize the performance of processes and hardware which are important to ISPP concepts and to demonstrate how these processes and hardware interact with the Mars environment. Operating this hardware in the actual Mars environment is extremely important due to both uncertainties in our knowledge of the Mars environment as well as because of conditions that cannot be adequately simulated on Earth. The MIP Flight Demonstration is a payload onboard the MARS SURVEYOR Lander and will be launched in April 2001. MIP will be the first hardware to utilize the indigenous resources of a planet or moon. Its successful operation will pave the way for future robotic and human missions to rely on propellants produced using Martian resources as feedstock.

Kaplan, D. I.↗

Information Technology and the Autonomous Control of a Mars In-Situ Propellant Production System

With the rapidly increasing performance of information technology, i.e., computer hardware and software systems, as well as networks and communication systems, a new capability is being developed that holds the clear promise of greatly increased exploration capability, along with dramatically reduced design, development, and operating costs. These new intelligent systems technologies, utilizing knowledge-based software and very high performance computer systems, will provide new design and development tools, scheduling mechanisms, and vehicle and system health monitoring capabilities. In addition, specific technologies such as neural nets will provide a degree of machine intelligence and associated autonomy which has previously been unavailable to the mission and spacecraft designer and to the system operator. One of the most promising applications of these new information technologies is to the area of in situ resource utilization. Useful resources such as oxygen, compressed carbon dioxide, water, methane, and buffer gases can be extracted and/or generated from planetary atmospheres, such as the Martian atmosphere. These products, when used for propulsion and life-support needs can provide significant savings in the launch mass and costs for both robotic and crewed missions. In the longer term the utilization of indigenous resources is an enabling technology that is vital to sustaining long duration human presence on Mars. This paper will present the concepts that are currently under investigation and development for mining the Martian atmosphere, such as temperature-swing adsorption, zirconia electrolysis etc., to create propellants and life-support materials. This description will be followed by an analysis of the information technology and control needs for the reliable and autonomous operation of such processing plants in a fault tolerant manner, as well as the approach being taken for the development of the controlling software. Finally, there will be a brief discussion of the verification and validation process so crucial to the implementation of mission-critical software.

Gross, Anthony R.↗