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Space construction data base

Construction of large systems in space is a technology requiring the development of construction methods to deploy, assemble, and fabricate the elements comprising such systems. A construction method is comprised of all essential functions and operations and related support equipment necessary to accomplish a specific construction task in a particular way. The data base objective is to provide to the designers of large space systems a compendium of the various space construction methods which could have application to their projects.

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Specific construction tests

The technical feasibility of the Satellite Power System (SPS) is discussed. The development of feasible operational concepts and conceptualization of specific construction tasks are examined. The logic flow of functional analyses of both the rectenna and the satellite is illustrated. Constraints placed upon the construction processes and equipment by the satellite design are outlined. The construction tasks, when defined and combined into an integrated schedule establish, a time line for construction mass flow demands to be satisfied by the space transportation systems. An example of satellite constructive demands and HLLV delivery capabilities is given.

Mcrae, W. V., Jr.↗

A lunar construction shack vehicle: Final design

A lunar construction shack vehicle is a critical component in most of the plans proposed for the construction of a permanent base on the moon. The Selene Engineering Company (SEC) has developed a concept for this vehicle which is both innovative and practical. The design makes use of the most advanced technology available to meet the goals for a safe, versatile and durable habitat that will serve as a starting point for the initial phase of the construction of a permanent lunar base. This document outlines SEC's proposed design for a lander vehicle which will be fully self-sufficient and will provide for all necessary life support, including consumables and radiation protection, needed by the construction crew until they can complete the assembly of a more permanent habitat. Since it is highly likely that it will take more than one crew to complete the construction of a permanent lunar base, the design emphasis is on systems which can be easily maintained and resupplied and which will take a minimum of start up preparation by succeeding crews.

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Telerobotics design issues for space construction

The use of a Flight Telerobotic Servicer (FTS) in the construction of the Space Station is examined. A methodology is presented for evaluating possible construction tasks, telerobotic performance capabilities, development costs, and operational constraints. The use of telerobotics as a substitute for human EVA activities and the construction tasks which an FTS could perform in the next 8-10 years are considered. The cost-effectiveness of construction using the FTS is compared with that of construction using the STS. The trade-offs associated with using the FTS are discussed in detail.

Smith, Jeffrey H.↗

Construction of dynamic stochastic simulation models using knowledge-based techniques

Over the past three decades, computer-based simulation models have proven themselves to be cost-effective alternatives to the more structured deterministic methods of systems analysis. During this time, many techniques, tools and languages for constructing computer-based simulation models have been developed. More recently, advances in knowledge-based system technology have led many researchers to note the similarities between knowledge-based programming and simulation technologies and to investigate the potential application of knowledge-based programming techniques to simulation modeling. The integration of conventional simulation techniques with knowledge-based programming techniques is discussed to provide a development environment for constructing knowledge-based simulation models. A comparison of the techniques used in the construction of dynamic stochastic simulation models and those used in the construction of knowledge-based systems provides the requirements for the environment. This leads to the design and implementation of a knowledge-based simulation development environment. These techniques were used in the construction of several knowledge-based simulation models including the Advanced Launch System Model (ALSYM).

Williams, M. Douglas↗

Erosion versus construction: The origin of Venusian channels

Lava channels are a common feature in the volcanic regions of the Moon, and have now been observed on Venus. There has been much debate about the origin of lunar channels as to whether they are the result of erosional (either thermal or mechanical) or constructional processes. It is necessary to determine the criteria to distinguish between the different types of channels. The clearest evidence is that the presence of levees indicates that the channel experienced a constructional phase for a period. One example of a channel of this type in the southeast region of Aphrodite Terra appears to show both erosional and constructional characteristics. It is approximately 700 km long with an average width of about 1 km. It drops a distance of 700 m from beginning to end, which means that the average slope is 0.06 degrees. Its source may have been a graben situated at the northwest end of the channel. It appears to have different origins along its length. The lack of levees near the source suggests that the channel is erosional in this region. The presence of levees indicates that a constructional phase has occurred. These are formed by lava repeatedly splashing over the channel sides and solidifying. Evidence of levees is seen further away from the source. However, the presence of levees does not mean that the lava was not also eroding and deepening the channel. Thus, in conclusion, our example channel is very sinuous and there is evidence of erosion. There may also have been overflow here. In its middle reaches it roofs over and has the characteristics of a lava tube. In the lower reaches there is strong evidence for the presence of levees indicating construction. On Earth, limited amounts of erosion may occur in basaltic lava channels, although not nearly on the same scale as on the planets just mentioned. For lava erosion on Earth to occur to a comparable extent, excessive eruption times are required. However, low-viscosity komatiite lava may erode to a larger extent and there is direct evidence that carbonatite lava erodes when the underlying strata is also carbonatite. Previously, it has always been assumed that for thermal erosion to occur the flow must be turbulent. Recent findings indicate that this may be a false assumption and that laminar flow may be effective in eroding the substrate.

Bussey, D. B. J.↗

Space construction activities

The Center for Space Construction at the University of Colorado at Boulder was established in 1988 as a University Space Engineering Research Center. The mission of the Center is to conduct interdisciplinary engineering research which is critical to the construction of future space structures and systems and to educate students who will have the vision and technical skills to successfully lead future space construction activities. The research activities are currently organized around two central projects: Orbital Construction and Lunar Construction. Summaries of the research projects are included.

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The challenge of constraining mass for planetary construction

The challenges facing the designers of planetary construction machinery, construction methods, and indigenous construction materials are examined. Machinery and methods are studied from the perspective of mass and power constraints, and indigenous material use is viewed from a technical and mass-benefit vantage point. It is argued that the value of an object on the lunar surface is inexorably linked to its mass due to the high cost of space transportation. Payload capabilities and delivery costs for selected U.S. launch vehicles are given in tabular form. Power vs mass for selected construction vehicles and lunar surface hardware is illustrated. It is concluded that construction materials must be evaluated on their mass-cost of production vs the mass of equal materials delivered direct. Machinery must be designed to be both mass and power efficient, with a premium on performance per unit of mass and power.

Connolly, John F.↗

Communications among elements of a space construction ensemble

Space construction projects will require careful coordination between managers, designers, manufacturers, operators, astronauts, and robots with large volumes of information of varying resolution, timeliness, and accuracy flowing between the distributed participants over computer communications networks. Within the CSC Operations Branch, we are researching the requirements and options for such communications. Based on our work to date, we feel that communications standards being developed by the International Standards Organization, the CCITT, and other groups can be applied to space construction. We are currently studying in depth how such standards can be used to communicate with robots and automated construction equipment used in a space project. Specifically, we are looking at how the Manufacturing Automation Protocol (MAP) and the Manufacturing Message Specification (MMS), which tie together computers and machines in automated factories, might be applied to space construction projects. Together with our CSC industrial partner Computer Technology Associates, we are developing a MAP/MMS companion standard for space construction and we will produce software to allow the MAP/MMS protocol to be used in our CSC operations testbed.

Davis, Randal L.↗

Meta-Modeling: A Knowledge-Based Approach to Facilitating Model Construction and Reuse

In this paper, we introduce a new modeling approach called meta-modeling and illustrate its practical applicability to the construction of physically-based ecosystem process models. As a critical adjunct to modeling codes meta-modeling requires explicit specification of certain background information related to the construction and conceptual underpinnings of a model. This information formalizes the heretofore tacit relationship between the mathematical modeling code and the underlying real-world phenomena being investigated, and gives insight into the process by which the model was constructed. We show how the explicit availability of such information can make models more understandable and reusable and less subject to misinterpretation. In particular, background information enables potential users to better interpret an implemented ecosystem model without direct assistance from the model author. Additionally, we show how the discipline involved in specifying background information leads to improved management of model complexity and fewer implementation errors. We illustrate the meta-modeling approach in the context of the Scientists' Intelligent Graphical Modeling Assistant (SIGMA) a new model construction environment. As the user constructs a model using SIGMA the system adds appropriate background information that ties the executable model to the underlying physical phenomena under investigation. Not only does this information improve the understandability of the final model it also serves to reduce the overall time and programming expertise necessary to initially build and subsequently modify models. Furthermore, SIGMA's use of background knowledge helps eliminate coding errors resulting from scientific and dimensional inconsistencies that are otherwise difficult to avoid when building complex models. As a. demonstration of SIGMA's utility, the system was used to reimplement and extend a well-known forest ecosystem dynamics model: Forest-BGC.

Keller, Richard M.↗

TOPS On-Line: Automating the Construction and Maintenance of HTML Pages

After the Technology Opportunities Showcase (TOPS), in October, 1993, Langley Research Center's (LaRC) Information Systems Division (ISD) accepted the challenge to preserve the investment in information assembled in the TOPS exhibits by establishing a data base. Following the lead of several people at LaRC and others around the world, the HyperText Transport Protocol (HTTP) server and Mosaic were the obvious tools of choice for implementation. Initially, some TOPS exhibitors began the conventional approach of constructing HyperText Markup Language (HTML) pages of their exhibits as input to Mosaic. Considering the number of pages to construct, a better approach was conceived that would automate the construction of pages. This approach allowed completion of the data base construction in a shorter period of time using fewer resources than would have been possible with the conventional approach. It also provided flexibility for the maintenance and enhancement of the data base. Since that time, this approach has been used to automate construction of other HTML data bases. Through these experiences, it is concluded that the most effective use of the HTTP/Mosaic technology will require better tools and techniques for creating, maintaining and managing the HTML pages. The development and use of these tools and techniques are the subject of this document.

Jones, Kennie H.↗

Development of Additive Construction Technologies for Application to Development of Lunar/Martian Surface Structures Using In-Situ Materials

For long-duration missions on other planetary bodies, the use of in situ materials will become increasingly critical. As human presence on these bodies expands, so must the breadth of the structures required to accommodate them including habitats, laboratories, berms, radiation shielding for natural radiation and surface reactors, garages, solar storm shelters, greenhouses, etc. Planetary surface structure manufacturing and assembly technologies that incorporate in situ resources provide options for autonomous, affordable, pre-positioned environments with radiation shielding features and protection from micrometeorites, exhaust plume debris, and other hazards. The ability to use in-situ materials to construct these structures will provide a benefit in the reduction of up-mass that would otherwise make long-term Moon or Mars structures cost prohibitive. The ability to fabricate structures in situ brings with it the ability to repair these structures, which allows for the self-sufficiency and sustainability necessary for long-duration habitation. Previously, under the auspices of the MSFC In-Situ Fabrication and Repair (ISFR) project and more recently, under the jointly-managed MSFC/KSC Additive Construction with Mobile Emplacement (ACME) project, the MSFC Surface Structures Group has been developing materials and construction technologies to support future planetary habitats with in-situ resources. One such additive construction technology is known as Contour Crafting. This paper presents the results to date of these efforts, including development of novel nozzle concepts for advanced layer deposition using this process. Conceived initially for rapid development of cementitious structures on Earth, it also lends itself exceptionally well to the automated fabrication of planetary surface structures using minimally processed regolith as aggregate, and binders developed from in situ materials as well. This process has been used successfully in the fabrication of construction elements using lunar regolith simulant and Mars regolith simulant, both with various binder materials. Future planned activities will be discussed as well.

Werkheiser, Niki J.↗

On The Development of Additive Construction Technologies for Application to Development of Lunar/Martian Surface Structures Using In-Situ Materials

For long-duration missions on other planetary bodies, the use of in-situ materials will become increasingly critical. As man's presence on these bodies expands, so must the breadth of the structures required to accommodate them including habitats, laboratories, berms, radiation shielding for natural radiation and surface reactors, garages, solar storm shelters, greenhouses, etc. Planetary surface structure manufacturing and assembly technologies that incorporate in-situ resources provide options for autonomous, affordable, pre-positioned environments with radiation shielding features and protection from micrometeorites, exhaust plume debris, and other hazards. This is important because gamma and particle radiation constitute a serious but reducible threat to long-term survival of human beings, electronics, and other materials in space environments. Also, it is anticipated that surface structures will constitute the primary mass element of lunar or Martian launch requirements. The ability to use in-situ materials to construct these structures will provide a benefit in the reduction of up-mass that would otherwise make long-term Moon or Mars structures cost prohibitive. The ability to fabricate structures in situ brings with it the ability to repair these structures, which allows for self-sufficiency necessary for long-duration habitation. Previously, under the auspices of the MSFC In Situ Fabrication and Repair (ISFR) project and more recently, under the joint MSFC/KSC Additive Construction with Mobile Emplacement (ACME) project, the MSFC Surface Structures Group has been developing materials and construction technologies to support future planetary habitats with in situ resources. One such technology, known as Contour Crafting (additive construction), is shown in Figure 1, along with a typical structure fabricated using this technology. This paper will present the results to date of these efforts, including development of novel nozzle concepts for advanced layer deposition using the Contour Crafting process. This process, conceived initially for rapid development of cementitious structures on Earth, also lends itself exceptionally well to the automated fabrication of planetary surface structures using minimally processed regolith as aggregate, and imported binder material or binders developed from in situ materials. This process has been used successfully in the fabrication of construction elements using lunar regolith simulant and Mars regolith simulant, both with various binder materials. These binder materials have resulted from extensive evaluation and include both "imported" binder materials that might be launched from Earth as well as some binder materials that can theoretically also be derived from existing regolith materials. They were chosen to 1) reduce penetrating radiation as much as possible, primarily with hydrogen-bearing polymers, 2) attempt to provide an air-tight structure, 3) sufficiently mix and adsorb to regolith grains for strength, 4) maximize tolerance to day-night thermal cycling, 5) possibly increase electrical conductivity to dissipate any accumulated static charge, and 6) ease their application on planetary surfaces (specifically, the accommodation of reduced atmosphere and lack of heat sinks). Some of these materials have been tested with respect to radiation mitigation, micrometeorite resistance, and resistance to larger, slower-traveling pieces of regolith impinging on the surface, simulating nearby launch and landing activities. Conceptual designs for a Continuous Feedstock Delivery/Mixing System (CFDMS) will also be presented and future planned activities will be discussed as well.

Werkheiser, Niki↗

Weighted Least-Squares Cell-Average Gradient Construction Methods for the VULCAN-CFD Second-Order Accurate Unstructured-Grid Cell-Centered Finite-Volume Solver

The ability to solve the equations governing the hypersonic turbulent flow of a real gas on unstructured grids using a spatially-elliptic, 2nd-order accurate, cell-centered, finite-volume method has been recently implemented in the VULCAN-CFD code. The construction of cell-average gradients using a weighted linear least-squares method and the use of these gradients in the construction of the inviscid fluxes is the focus of this paper. A comparison of least-squares stencil construction methodologies is presented and approaches to augment the number of cells participating in the stencil while preserving accuracy are explored. Due to our interest in hypersonic flow, a robust multidimensional cell-average gradient limiter procedure that is consistent with the stencil used to construct the cell-average gradients is described and investigated. Canonical problems are computed to illustrate the challenges and investigate the accuracy, robustness and convergence behavior of the cell-average gradient methods on unstructured cell-centered finite-volume grids. Finally, thermally perfect, chemically frozen, Mach 8 turbulent flow of air around a blunt wedge is computed to demonstrate the robustness and convergence behavior of the new method for constructing stencils of use in a weighted linear least-squares gradient method for a hypersonic flow.

White, Jeffery A.↗

Lunar Mega Project: Processes, Work Flow and Terminology of the Terrestrial Construction Industry versus the Space Industry

Recent developments around the world show an increased interest and international activity toward developing a lunar surface human and robotic presence with a long term, sustainable vision. In Europe, the construction of a "Moon Village" has been proposed, and China has stated its intention to build a research station with a crew at the lunar South Pole. Russia stated it will land cosmonauts on the Moon in the 2030's. India has sent an orbiter, a robotic lander, and rover to the Moon. The USA intends to land the first woman and a man on the Moon by 2024 to initiate a sustained human lunar presence.A lunar research station with associated commercial activities will require infrastructure to become a permanent capability. Landing and launch pads, propellant storage and distribution farms, spacecraft access and handling structures, cranes, blast protection berms or walls, roads, graded areas, dust stabilized areas, foundations, parking lots, radiation shelters, micro-meteorite protection hangars, habitats and other human shelters, greenhouse farms, utility trenches, power plants, industrial water and oxygen extraction plants, communications antenna towers, thermal protection, mining zones, crater access and sub-surface access will be required to create a safe and sustainable lunar operations capability. This infrastructure will require significant construction activities in an extreme environment, with risky and expensive operations. On Earth, there are similar large and expensive projects (>$1 Billion) in difficult locations that attract a lot of public attention. These are known as "Mega Projects" and examples include bridges, tunnels, highways, railways, airports, seaports, power plants, dams, wastewater projects, Special Economic Zones (SEZ), oil and natural gas extraction projects, public buildings, information technology systems, aerospace projects, and weapons systems. Large consortiums consisting of public and private entities typically implement these infrastructure Mega-Projects.This paper will compare the typical design process, project management process, and work flow in the terrestrial construction industry to the space industry in order to create a better understanding between the terrestrial construction industry and the space industry, to further enable collaboration on a lunar Mega Project to build infrastructure on the Moon. In addition, a glossary of respective industry terminology with annotated linkages and definitions has been compiled. This information will enable contracts and business practices to be formulated for generating requests for proposals (RFP) by governments to consortiums consisting of construction and space industry companies that will bid on Lunar Infrastructure Projects that could lead to contracts to build the permanent capabilities.

Robert P Mueller↗

Development of the Advanced Regolith Ground Operations (ARGO) Test Bed– A Robotic Construction Test Facility with Simulated Lunar Environments

NASA’s Artemis Program is working towards developing a sustained presence on the Moon and eventually Mars. To achieve this goal, robotic excavation, site preparation and construction technologies are under development to establish the capability to construct infrastructure such as launch/landing pads and radiation protection shelters. Technologies must be proven in simulated Lunar conditions prior surface demonstration missions. To that end, the Relevant Additive Construction Technology (REACT) Announcement of Collaboration Opportunities (ACO) project with AI Space Factory and the NASA Kennedy Space Center’s (KSC) Granular Mechanics and Regolith Operations Laboratory (a.k.a. Swamp Works) has developed the Advanced Regolith Ground Operations (ARGO) Test Bed. ARGO includes a ~1.5m x 1.5m x 1.2m (~5x5x4ft) vacuum chamber, cryogenically cooled thermal shroud, a 3-axis robotic positioning system, and a regolith bin. For the REACT project, a pellet extruder and feed hopper have been installed on ARGO to advance the Technology Readiness Level (TRL) of regolith-polymer composite Fused Deposition Modeling (FDM) additive construction systems, processes, and materials. This paper will focus on the design and operational characteristics of the ARGO Test Bed with pellet extruder.

Moon↗

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↗

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↗