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NASA NTRS2024

Terrestrial Proving Ground Capabilities Needed for Lunar In Situ Resource Utilization (ISRU) & Construction Concepts of Operation

Incorporating any new technology or system into a human exploration mission or architecture requires development well in advance of the mission to eliminate technology, cost, and schedule risk concerns. It is often stated that technologies need to be at a Technology Readiness Level (TRL) of 6, i.e. ‘system/subsystem model or prototype demonstration in a relevant environment (ground or space)’, by Authority To Proceed (ATP) or by the Preliminary Design Review (PDR) for the mission at the latest. There are two game changing capabilities for sustained human exploration of space that can have a significant effect on the overall exploration architecture and the technologies and systems included in the architecture. The first game changing capability, known as In Situ Resource Utilization (ISRU), involves the search for, acquisition, and processing of resources on the Moon and Mars into mission consumables and usable products, and the second is the ability to utilize space resources in the construction of roads, structures, and surface infrastructure. ISRU and surface construction capabilities have the potential to greatly reduce the cost and risk of human exploration while enabling sustained lunar surface and commercial operations. However, ISRU and surface construction systems are complex and must operate in extremely harsh environments, with abrasive regolith and pervasive dust, for long-periods of time, with potentially limited opportunities for maintenance and repair by humans. The complexity of these capabilities and operations also means that there are a limited number of companies that can design, build, and operate end-to-end systems on their own. The majority of the technologies being developed for these systems are by small companies and at the component or subsystem level. With the overarching strategy of the United States National Aeronautics and Space Administration (NASA) Space Technology Mission Directorate (STMD) to enable industry to implement ISRU and surface infrastructure for Artemis and space commercialization, it is therefore important to establish processes and capabilities to promote and foster collaborations among large and small companies involved in ISRU and surface infrastructure development. For ISRU and infrastructure systems and capabilities to be used in Artemis missions and future commercial lunar surface operations, a coordinated framework with virtual/physical integration and testing locations, or ‘Proving Grounds’, needs to be established and operated on a regular basis and open to all. This paper will discuss the ISRU and surface construction near and long-term concepts of operations, and review operations and lessons-learned from the previous ISRU analog field tests. From this information, requirements and capabilities will be proposed to support and enable the integration and testing of ISRU and construction systems with industry, academia, and international agencies, as well as what facilities and organizations could help establish these Proving Grounds.

ISRU↗
NASA NTRSDate not supplied

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↗
NASA NTRS1990

Conceptual design and analysis of roads and road construction machinery for initial lunar base operations

Recent developments have made it possible for scientists and engineers to consider returning to the Moon to build a manned lunar base. The base can be used to conduct scientific research, develop new space technology, and utilize the natural resources of the Moon. Areas of the base will be separated, connected by a system of roads that reduce the power requirements of vehicles traveling on them. Feasible road types for the lunar surface were analyzed and a road construction system was designed for initial lunar base operations. A model was also constructed to show the system configuration and key operating features. The alternate designs for the lunar road construction system were developed in four stages: analyze and select a road type; determine operations and machinery needed to produce the road; develop machinery configurations; and develop alternates for several machine components. A compacted lunar soil road was selected for initial lunar base operations. The only machinery required to produce this road were a grader and a compactor. The road construction system consists of a main drive unit which is used for propulsion, a detachable grader assembly, and a towed compactor.

Sines, Jeffrey L.↗
NASA NTRSDate not supplied

From Regolith to Living Off the Land: Formulating a Data Model to Catalog Lunar Construction Materials

Artemis Program objectives for sustainable, long-term presence on the Moon and more distant planetary surfaces will require learning to “Live off the Land”, relying on in-situ resource utilization to produce infrastructure and building materials from lunar regolith, icy subsurface deposits, and residual waste materials. Meeting demand for consumables while scaling development with resources found within the landing zone will require detailed data on the geology and environment of the lunar surface. Lunar infrastructure development will generate vast amounts of new engineering data regarding availability of processed feedstocks and their performance in building materials. Lunar engineering data accessible to program partners, research institutions and industry may help situate processes and specifications within the in-situ GIS context. Lunar missions to date have generated geological and ice favorability maps of the lunar surface, and recent technology studies have tested automated construction systems and novel material formulations using regolith simulants and binders. Current discussions focus on identifying key feedstocks, quantities required for nominal mission scenarios and infrastructure plans, and mapping the value chain from regolith to feedstock to consumables and construction materials.

lunar construction↗
NASA NTRSDate not supplied

From Regolith to Living Off the Land: Formulating a Data Model to Catalog Lunar Construction Materials

Artemis Program objectives for sustainable, long-term presence on the Moon and more distant planetary surfaces will require learning to “Live off the Land”, relying on in-situ resource utilization to produce infrastructure and building materials from lunar regolith, icy subsurface deposits, and residual waste materials. Meeting demand for consumables while scaling development with resources found within the landing zone will require detailed data on the geology and environment of the lunar surface. Lunar infrastructure development will generate vast amounts of new engineering data regarding availability of processed feedstocks and their performance in building materials. Lunar engineering data accessible to program partners, research institutions and industry may help situate processes and specifications within the in-situ GIS context. Lunar missions to date have generated geological and ice favorability maps of the lunar surface, and recent technology studies have tested automated construction systems and novel material formulations using regolith simulants and binders. Current discussions focus on identifying key feedstocks, quantities required for nominal mission scenarios and infrastructure plans, and mapping the value chain from regolith to feedstock to consumables and construction materials.

lunar construction↗
NASA NTRS2006

Haughton-Mars Project (HMP)/NASA 2006 Lunar Medical Contingency Simulation: An Overview

Medical requirements are currently being developed for NASA's space exploration program. Lunar surface operations for crews returning to the moon will be performed on a daily basis to conduct scientific research and construct a lunar habitat. Inherent to aggressive surface activities is the potential risk of injury to crew members. To develop an evidence-base for handling medical contingencies on the lunar surface, a simulation project was conducted using the moon-Mars analog environment at Devon Island, Nunavut, high Canadian Arctic. A review of the Apollo lunar surface activities and personal communications with Apollo lunar crew members provided a knowledge base of plausible scenarios that could potentially injure an astronaut during a lunar extravehicular activity. Objectives were established to 1) demonstrate stabilization, field extraction and transfer an injured crew member to the habitat and 2) evaluate audio, visual and biomedical communication capabilities with ground controllers at multiple mission control centers. The simulation project s objectives were achieved. Among these objectives were 1) extracting a crew member from a sloped terrain by a two-member team in a 1-g analog environment, 2) establishing real-time communication to multiple space centers, 3) providing biomedical data to flight controllers and crew members, and 4) establishing a medical diagnosis and treatment plan from a remote site. The simulation project provided evidence for the types of equipment and methods needed for planetary space exploration. During the project, the crew members were confronted with a number of unexpected scenarios including environmental, communications, EVA suit, and navigation challenges. These trials provided insight into the challenges of carrying out a medical contingency in an austere environment. The knowledge gained from completing the objectives of this project will be incorporated into the exploration medical requirements involving an incapacited astronaut on the lunar surface.

Scheuring, R. A.↗
NASA NTRS1984

Toward a lunar base

A research program leading to the development of a design for a permanent manned lunar base is described. Attention is given to the advantages offered by the lunar environment for materials processing and scientific investigations, due to the absence of an atmosphere and the plentiful supply of certain materials (iron and titanium). It is shown that once a controlled environment capsule is placed on the lunar surface, work could begin toward the construction of a permanent facility using lunar materials. It is pointed out that the research effort required for the design of a lunar base could perform concurrently with the R&D for the Space Station, resulting in the emplacement of a controlled environment capsule by the year 2007.

Duke, M. B.↗
NASA NTRS2010

HDU Pressurized Excursion Module (PEM) Prototype Systems Integration

The Habitat Demonstration Unit (HDU) project team constructed an analog prototype lunar surface laboratory called the Pressurized Excursion Module (PEM). The prototype unit subsystems were integrated in a short amount of time, utilizing a skunk-works approach that brought together over 20 habitation-related technologies from a variety of NASA centers. This paper describes the system integration strategies and lessons learned, that allowed the PEM to be brought from paper design to working field prototype using a multi-center team. The system integration process included establishment of design standards, negotiation of interfaces between subsystems, and scheduling fit checks and installation activities. A major tool used in integration was a coordinated effort to accurately model all the subsystems using CAD, so that conflicts were identified before physical components came together. Some of the major conclusions showed that up-front modularity that emerged as an artifact of construction, such as the eight 45 degree "pie slices" making up the module whose steel rib edges defined structural mounting and loading points, dictated much of the configurational interfaces between the major subsystems and workstations. Therefore, 'one of the lessons learned included the need to use modularity as a tool for organization in advance, and to work harder to prevent non-critical aspects of the platform from dictating the modularity that may eventually inform the fight system.

Gill, Tracy R.↗
NASA NTRS1991

Consolidation of lunar regolith: Microwave versus direct solar heating

The production of construction materials on the lunar surface will require an appropriate fabrication technique. Two processing methods considered as being suitable for producing dense, consolidated products such as bricks are direct solar heating and microwave heating. An analysis was performed to compare the two processes in terms of the amount of power and time required to fabricate bricks of various size. The regolith was considered to be a mare basalt with an overall density of 60 pct. of theoretical. Densification was assumed to take place by vitrification since this process requires moderate amounts of energy and time while still producing dense products. Microwave heating was shown to be significantly faster compared to solar furnace heating for rapid production of realistic-size bricks.

Kunitzer, J.↗
NASA NTRS2011

Habitat Demonstration Unit (HDU) Pressurized Excursion Module (PEM) Systems Integration Strategy

The Habitat Demonstration Unit (HDU) project team constructed an analog prototype lunar surface laboratory called the Pressurized Excursion Module (PEM). The prototype unit subsystems were integrated in a short amount of time, utilizing a rapid prototyping approach that brought together over 20 habitation-related technologies from a variety of NASA centers. This paper describes the system integration strategies and lessons learned, that allowed the PEM to be brought from paper design to working field prototype using a multi-center team. The system integration process was based on a rapid prototyping approach. Tailored design review and test and integration processes facilitated that approach. The use of collaboration tools including electronic tools as well as documentation enabled a geographically distributed team take a paper concept to an operational prototype in approximately one year. One of the major tools used in the integration strategy was a coordinated effort to accurately model all the subsystems using computer aided design (CAD), so conflicts were identified before physical components came together. A deliberate effort was made following the deployment of the HDU PEM for field operations to collect lessons learned to facilitate process improvement and inform the design of future flight or analog versions of habitat systems. Significant items within those lessons learned were limitations with the CAD integration approach and the impact of shell design on flexibility of placing systems within the HDU shell.

Gill, Tracy↗
NASA NTRSDate not supplied

2024 Nasa Lunabotics University Competition: Site Preparation With Bulk Regolith

Introduction: Lunabotics provides accredited institutions of higher learning students (vocational-technical, college, university) an opportunity to apply the NASA systems engineering process to design and build a prototype robot. This robot would be capable of performing the proposed operations on the Lunar surface in support of future Artemis mission goals. Lunabotics features a systems engineering design challenge to engage students in the next phase of hu-man space exploration supporting the Artemis missions. This two-semester event encourages students to design and build an autonomous or telerobotic robot designed to traverse the simulated Lunar surface and complete the assigned construction tasks. The number of teams accepted into this challenge is not predetermined but is based on the scores and overall quality of the Project Management Plans received and other factors. The culmination of the Lunabotics virtual challenge will be the design, build and operation of a functional prototype Lunar robot. Teams are required to submit the following: (1) Project Management Plan, (2) Systems Engineering Paper, a (3) STEM Engage-ment Report, and a (4) Proof of Life Video. This is an optional item, but to qualify for the grand prize a team must also submit a: (5) Presentation and Demonstration. Background: The NASA Lunabotics University Competition was first held in 2010 as a follow on to the NASA Regolith Excavation Challenge [1]. The high level of interest and participation from over 50 universities each year has led to a sustained annual competi-ion cadence: it has been held every May for the past 14 years [2,3]. Over 6,000 students have participated and been inspired to pursue Science, Technology, En-gineering and Mathematics careers (STEM). 2024 Competition: The necessary lunar surface tasks are evolving to meet the NASA Artemis Mission requirements. In the past Lunabotics challenges we gathered data to support Lunar mining for consuma-bles in the Lunar regolith. Now, in 2024, the task is to gather data on Lunar site preparation and construction by designing and building a robot that will traverse the chaotic Lunar terrain and construct a regolith-based berm. The goal is to build a berm structure which would be useful to the Artemis Mission for blast and ejecta protection during lunar landings and launches, shading cryogenic propellant tank farms, providing radiation protection around a nuclear power plant and other mission critical uses. Lunabotics will consist of three separate events this year. The first event is NASA’s Lunabotics Project Development Challenge, where teams submit various deliverables to be scored by judges. The second event will be the University of Central Florida (UCF) Lunabotics Qualification challenge, in the Exolith laboratory, where teams will put their de-signs to the test. The top ten scoring teams from the Qualification challenge are then invited to the third and final event, NASA’s Lunabotics On-Site Challenge at Kennedy Space Center in Florida. This presentation will summarize the results and lessons learned from the NASA Lunabotics University Competition held in May 2024.

Lunabotics↗
NASA NTRS2008

Design and Field Test of a Mass Efficient Crane for Lunar Payload Handling and Inspection: The Lunar Surface Manipulation System

Devices for lifting, translating and precisely placing payloads are critical for efficient Earthbased construction operations. Both recent and past studies have demonstrated that devices with similar functionality will be needed to support lunar outpost operations. Lunar payloads include: a) prepackaged hardware and supplies which must be unloaded from landers and then accurately located at their operational site, b) sensor packages used for periodic inspection of landers, habitat surfaces, etc., and c) local materials such as regolith which require grading, excavation and placement. Although several designs have been developed for Earth based applications, these devices lack unique design characteristics necessary for transport to and use on the harsh lunar surface. These design characteristics include: a) composite components, b) compact packaging for launch, c) simple in-field reconfiguration and repair, and d) support for tele-operated or automated operations. Also, in contrast to Earth-based construction, where special purpose devices dominate a construction site, a lunar outpost will require versatile devices which provide operational benefit from initial construction through sustained operations. This paper will detail the design of a unique, high performance, versatile lifting device designed for operations on the lunar surface. The device is called the Lunar Surface Manipulation System to highlight the versatile nature of the device which supports conventional cable suspended crane operations as well as operations usually associated with a manipulator such as precise positioning where the payload is rigidly grappled by a tool attached to the tip of the device. A first generation test-bed to verify design methods and operational procedures is under development at the NASA Langley Research Center and recently completed field tests at Moses Lake Washington. The design relied on non-linear finite element analysis which is shown to correlate favorably with laboratory experiments. A key design objective, reviewed in this paper, is the device s simplicity, resulting from a focus on the minimum set of functions necessary to perform payload offload. Further development of the device has the potential for significant mass savings, with a high performance device incorporating composite elements estimated to have a mass less than 3% of the mass of the maximum lunar payload lifted at the tip. The paper will conclude with future plans for expanding the operational versatility of the device.

Doggett, William R.↗
NASA NTRS1974

Refinement of the Goloseyev catalog point coordinates in the limb zone and determination of point coordinates on the back side of the moon

Lunar photography from Zond 6 showed half the side of the moon which is not visible from the earth, and this made it possible to construct a photogrammetric grid encompassing the entire Western Hemisphere and referenced to points of the visible side, whose coordinates were taken from the Goloseyev catalog. The problem was solved using two pictures taken from approximately 9000 km above the lunar surface. The photogrammetric grid was constructed by joint statistical analysis of the measurements of both pictures and the selenographic coordinates of the catalog points. A special algorithm was developed and a program compiled realizing the maximum likelihood method which permitted working with up to 120 catalog points simultaneously.

Krasikov, V. A.↗
NASA NTRSDate not supplied

NASA Lunar Surface Innovation Initiative: Ensuring a Cohesive, Executable Strategy for Technology Development

Establishing a sustainable human presence on the Moon allows NASA to develop and test new approaches, technologies, and systems that will enable us to function in other, more challenging environments. The Lunar Surface Innovation Initiative (LSII) was established in 2019 and has evolved into a key agency asset to spur technology development and provide risk reduction for lunar surface system development and flight demonstrations. LSII coordinates activities implemented through a combination of in-house activities, competitive programs, and public-private partnerships to create transformative technologies needed for lunar surface exploration. This paper will outline the LSII model used to develop a technology pipeline that will retire the primary technology hurdles in six capability areas. In-situ resource utilization technologies for collecting, processing, storing, and using material found or manufactured on the Moon. Surface power technologies that provide the capability for sustainable, continuous power throughout the day and night for lunar missions. Dust mitigation strategies that diminish lunar dust hazards on lunar surface systems such as cameras, solar panels, space suits, habitats, and instrumentation. Extreme environments technologies that enable systems to operate throughout the full range of lunar surface conditions, including lunar noon (up to 150 at the equator), night (down to - 180 at the equator), multiple day/night cycles, and in permanently shadowed regions (down to -250). Extreme access technologies that enable humans or robotic systems to access, navigate, and explore previously inaccessible lunar surface or subsurface areas. Excavation and construction technologies that will allow affordable, autonomous manufacturing or construction. We outline key results, including milestones and achievements related to the capability areas and outcomes from partnerships with the commercial sector. A key tenet of the LSII is the Lunar Surface Innovation Consortium (LSIC), a collaboration across industry, academia, and government to successfully develop the transformative capabilities for lunar surface exploration. LSIC provides a forum for NASA to communicate technological requirements, needs, and opportunities and for the community to share existing capabilities and identify critical gaps with NASA. By working side by side with commercial enterprises and our international partners, NASA is able to combine the knowledge and expertise needed to explore the lunar surface and make technical advances that will feed technological and economic growth. Since its inception, LSII has engaged over 600 organizations across the United States and 46 countries to shape the technologies and systems needed to explore the lunar surface and stimulate a lunar surface economy.

lunar, lunar surface, technology development, ISRU↗
NASA NTRSDate not supplied

NASA Lunar Surface Innovation Initiative: Ensuring a Cohesive, Executable Strategy for Technology

Establishing a sustainable human presence on the Moon allows NASA to develop and test new approaches, technologies, and systems that will enable us to function in other, more challenging environments. The Lunar Surface Innovation Initiative (LSII) was established in 2019 and has evolved into a key agency asset to spur technology development and provide risk reduction for lunar surface system development and flight demonstrations. LSII coordinates activities implemented through a combination of in-house activities, competitive programs, and public-private partnerships to create transformative technologies needed for lunar surface exploration. This paper will outline the LSII model used to develop a technology pipeline that will retire the primary technology hurdles in six capability areas. In-situ resource utilization technologies for collecting, processing, storing, and using material found or manufactured on the Moon. Surface power technologies that provide the capability for sustainable, continuous power throughout the day and night for lunar missions. Dust mitigation strategies that diminish lunar dust hazards on lunar surface systems such as cameras, solar panels, space suits, habitats, and instrumentation. Extreme environments technologies that enable systems to operate throughout the full range of lunar surface conditions, including lunar noon (up to 150 at the equator), night (down to - 180 at the equator), multiple day/night cycles, and in permanently shadowed regions (down to -250). Extreme access technologies that enable humans or robotic systems to access, navigate, and explore previously inaccessible lunar surface or subsurface areas. Excavation and construction technologies that will allow affordable, autonomous manufacturing or construction. We outline key results, including milestones and achievements related to the capability areas and outcomes from partnerships with the commercial sector. A key tenet of the LSII is the Lunar Surface Innovation Consortium (LSIC), a collaboration across industry, academia, and government to successfully develop the transformative capabilities for lunar surface exploration. LSIC provides a forum for NASA to communicate technological requirements, needs, and opportunities and for the community to share existing capabilities and identify critical gaps with NASA. By working side by side with commercial enterprises and our international partners, NASA is able to combine the knowledge and expertise needed to explore the lunar surface and make technical advances that will feed technological and economic growth. Since its inception, LSII has engaged over 600 organizations across the United States and 46 countries to shape the technologies and systems needed to explore the lunar surface and stimulate a lunar surface economy.

Lunar↗
NASA NTRS1990

Genesis lunar outpost criteria and design

This design study--the third in the space architecture series--focused on the requirements of an early stage lunar outpost. The driving assumptions of the scenario was that the base would serve as a research facility and technology testbed for future Mars missions, a habitat supporting 12 persons for durations of up to 20 months, and would sustain the following five experimental facilities: Lunar surface mining and production analysis facility, construction technology and materials testbed, closed environmental life support system (CELSS) test facility, lunar farside observatory, and human factors and environment-behavior research facility. Based upon the criteria set forth in a previous programming document, three preliminary lunar base designs were developed. Each of the three schemes studied a different construction method and configuration. The designs were then evaluated in terms of environmental response, human habitability, transportability, constructability, construction dependability and resilience, and their suitability in carrying out the desired scientific research. The positive points of each scheme were then further developed by the entire project team, resulting in one integrated lunar outpost design.

Hansmann, Timothy↗