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An integrated in-space construction facility for the 21st century

This paper presents preliminary results of studies currently being conducted by NASA for constructing very large spacecraft. The paper discusses the various approaches for constructing spacecraft and their relative merits. As currently planned, Space Station Freedom has incorporated all of the basic design characteristics to permit its growth into an in-space construction facility for very large spacecraft. If disturbances from construction operations are intolerable to other experiments on Space Station Freedom, a co-orbiting construction facility could be built using truss hardware and systems previously for developed Space Station Freedom. The new PATHFINDER research initiative for on-orbit assembly and construction is also discussed. This research effort is aimed at developing construction methods for very large spacecraft and includes the development of a 100-meter-long space crane.

Mikulas, Martin M., Jr.↗

Indigenous lunar construction materials

The utilization of local resources for the construction and operation of a lunar base can significantly reduce the cost of transporting materials and supplies from Earth. The feasibility of processing lunar regolith to form construction materials and structural components is investigated. A preliminary review of potential processing methods such as sintering, hot-pressing, liquification, and cast basalt techniques, was completed. The processing method proposed is a variation on the cast basalt technique. It involves liquification of the regolith at 1200-1300 C, casting the liquid into a form, and controlled cooling. While the process temperature is higher than that for sintering or hot-pressing (1000-1100 C), this method is expected to yield a true engineering material with low variability in properties, high strength, and the potential to form large structural components. A scenario for this processing method was integrated with a design for a representative lunar base structure and potential construction techniques. The lunar shelter design is for a modular, segmented, pressurized, hemispherical dome which could serve as habitation and laboratory space. Based on this design, estimates of requirements for power, processing equipment, and construction equipment were made. This proposed combination of material processing method, structural design, and support requirements will help to establish the feasibility of lunar base construction using indigenous materials. Future work will refine the steps of the processing method. Specific areas where more information is needed are: furnace characteristics in vacuum; heat transfer during liquification; viscosity, pouring and forming behavior of molten regolith; design of high temperature forms; heat transfer during cooling; recrystallization of basalt; and refinement of estimates of elastic moduli, compressive and tensile strength, thermal expansion coefficient, thermal conductivity, and heat capacity. The preliminary design of the lunar shelter showed us that joining is a critical technology needed for building a structure from large segments. The problem of joining is important to the design of any structure that is not completely prefabricated. It is especially important when the structure is subjected to tensile loading by an internal pressure. For a lunar shelter constructed from large segments the joints between these large segments must be strong, and they must permit automated construction. With a cast basalt building material which is brittle, there is the additional problem of connecting the joint with the material and avoiding stress concentration that would cause failure. Thus, a well-defined project which we intend to pursue during this coming year is the design of joints for cast basalt structural elements.

Rogers, Wayne P.↗

In Space Manufacturing and Extraterrestrial Construction: How Did We Get Here?Where Are We? Where Should We Be Going? THE CHALLENGE: Will We Be Ready?

NASA has held multiple workshops and sought inputs from a broad spectrum of sources, including international partners, other space agencies, industry, large and small businesses, academia, and private citizens to develop its Moon to Mars Strategy and Objectives. The goals and objectives set forth in the resulting documents are “designed to achieve the vision to create a blueprint for sustained human presence and exploration throughout the solar system.” The objectives were categorized into four distinct tracks: Operations, Infrastructure, Transportation and Habitation, and Science. In addition, common themes across the objectives were captured under Recurring Tenets. Within the Infrastructure category, several objectives directly address the need for manufacturing and construction on the lunar surface to support continuous human lunar presence and a robust lunar economy. In exploring the vision for creation of on-demand infrastructure on the lunar surface and beyond, this presentation will examine the development of these capabilities, starting in the late 1990’s and early 2000’s, up to the current state, and offer a perspective on the challenges facing operational implementation of these technologies. In the early 2000’s, the destination was the Moon. The International Space Station (ISS) was to be the test bed for demonstration of in space manufacturing technologies. Additive construction was in its infancy. These pioneering initiatives, having begun primarily under NASA’s Office of Biological and Physical Research In Situ Fabrication and Repair (ISFAR) Project, were short-lived. It was not until the early 2010’s that in space manufacturing and later extraterrestrial construction experienced renewed interest and support. At this time, the destination was Mars. This period saw the initial in space additive manufacturing experiments on the ISS, creation of a roadmap for development of in space manufacturing technologies, and development of additive construction systems for terrestrial use at scale. The period also included NASA’s 3D Printed Mars Habitat Centennial Challenge, which catalyzed interest in extraterrestrial construction. With NASA’s announcement of the intention to return to the Moon, and the subsequent release of the Artemis Accords in 2020, and the commensurate Moon to Mars Strategy, NASA’s Space Technology Mission Directorate initiated the Lunar Surface Innovation Initiative (LSII). The LSII has spurred technology development and maturation efforts across a spectrum of capabilities that would be needed to live on the lunar surface. The presentation will provide an overview of current technology developments in the areas of in space manufacturing and extraterrestrial construction. Looking forward from the current state, a perspective will be offered on capabilities that are still needed to “institutionalize” in space manufacturing and extraterrestrial construction to achieve the vision of NASA’s Moon to Mars Strategy. Finally, a challenge will be posed to the community to accelerate the development of these capabilities. When the explorers of the future need these enabling capabilities, will they be ready?

Raymond G Clinton Jr.↗

Benefits Of Automated Construction And Energy Efficiency Measures In Modular Homes

This article builds on and adds to a Buildings XV publication that introduced the Transformative Efficiency and Automation in Modular Homes (TEAMH) project. The TEAMH project sought to develop a scalable solution for producing modular homes with 20-50% energy savings and similar cost relative to site-fabricated single-family home construction. A key aspect of the project was assessing the potential for labor cost reductions through automation-assisted construction using light gauge steel (LGS). To quantify the advantages of this approach, side-by-side comparisons were made between traditional wood-framed construction and automation-assisted LGS construction. This demonstration involved constructing one wood-framed wall and several LGS test walls, accompanied by a time-and-motion study. The results indicated that automation assistance could decrease construction time and associated labor costs by as much as 46%. High-performance envelope technologies for exterior insulation and air sealing were evaluated to compare modular homes with site-built homes that meet the International Energy Conservation Code (IECC). A key technology considered was vacuum insulation panels (VIPs) with fiberglass cores. Guarded hot box testing of multiple full-scale wall assemblies containing different combinations of exterior continuous insulation systems containing phenolic foam and VIPs. Testing on various full-scale wall assemblies revealed that, with LGS construction, cavity insulation had minimal impact on exterior wall performance. Omitting cavity insulation can reduce labor and material costs while streamlining manufacturing, as its installation is labor-intensive and not easily automated due to the need for precise placement around wiring and other internal components. Guarded hot box tests of multiple LGS test walls with foam and VIP-based exterior insulation systems achieved R-values of up to 31 hr-ft2-°F/Btu. Finally, building energy modeling of multiple modular home designs indicated that the upgraded envelope assemblies can yield heating energy savings of up to 50% and cooling energy savings of up to 30% compared to IECC 2018 standards.

Shrestha, Som [ORNL] (ORCID:0000000183993797)↗

Understanding the Challenges of Financing Modular Construction: A Case Study for Prospective Multifamily Units

Compared to traditional site build, modular construction can significantly shorten construction schedules and speed income generation. Modular construction may also reduce construction costs. Yet access to commercial financing remains one of the most significant barriers to modular construction. Materials must be purchased, and production lines reconfigured for each project months ahead of fabrication. Materials alone can be 60% or more of the total cost of production. As a result, manufacturers require large upfront deposits—often 30% or more of the off-site contract. In addition, the capital-intensive nature of modular construction requires frequent progress payments for manufacturers to maintain cash flow. For those lenders willing to fund modular projects, many require the developer to share more of the risk. This may include the developer paying for line reservation fees and material deposits 3–6 months prior to production. Because these are unsecured loans, interest rates may be higher and loan amounts lower. As suppliers, modular manufacturers discourage retainage. Together, these and other factors may contribute to higher equity requirements for the developer—particularly at the beginning of the project.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

Relevant Environment Additive Construction Technology (REACT)

Project Overview This project is focused on developing technologies that enable construction of a Lunar Safe Haven type structure on the moon. A full scale architectural and structural design will be completed based on lunar conditions and Artemis mission needs. A scaled structure will be 3D printed in simulated lunar environments. Technical Approach Polymer bound regolith composite materials will be developed and characterized for lunar additive construction applications. A full scale architectural and structural design will be completed based on the latest scientific data on lunar environments including radiation, meteoroids, thermal conditions, reduced gravity, and moonquakes. The project will culminate with a demonstration of additive construction in simulated lunar vacuum, thermal, regolith, and UV conditions. Results/Summary Preliminary material specifications have been developed and an initial batch has been produced. A first iteration of the architectural and structural designs have been completed. Hardware for 3D printing in simulated lunar conditions is under development. Contributing Partners AI Space Factory – Winner of the NASA 3D Printed Habitat Centennial Challenge Infusion and Transition Plan On-surface construction of infrastructure is a critical capability of the sustainable phase of the Artemis Program and eventual sustainable human presence on Mars. It provides the ability to create protective shelters on-demand using local resources. The 3D-printing technology will achieve TRL 6 in 1g/vacuum tests with thermal/UV exposure in this project. CLPS missions will be pursued for infusion to demonstrate vertical construction with lunar regolith and conditions. Modeling and simulation will be used to define the pilot-scale shelter construction mission for long-term exposure on the lunar surface to validate the system for Artemis operational deployment.

Lunar Construction↗

Perspectives on Potential Advanced Construction Technologies for Nuclear Energy

Advanced reactor technologies have attracted considerable financial support, catalyzing innovation in the nuclear energy landscape. These next generation reactors are designed with enhanced passive safety systems and the potential for cost reductions. As these advanced reactors approach technological maturity, their commercial success also requires focused examination and essential support. Economic assessments in the nuclear energy sector often emphasize construction costs and the risk of scheduling delays as primary contributors to deployment expenditures. Traditionally, vital elements of nuclear energy deployment including civil/structural engineering, design sophistication and automation have been either undervalued or postponed in the development cycles. Additionally, the nuclear industry’s collective experience in nuclear project execution has diminished over the past several decades due to the infrequency of new plant constructions. Hence, the National Reactor Innovation Center’s (NRIC) Advanced Construction Technology Initiative (ACTI) aims to reduce cost overruns and schedule slippages that have plagued the construction of nuclear power plant projects. With this initiative, NRIC is facilitating the development of advanced nuclear plant construction technologies and approaches through partnerships that would provide game-changing benefits to the construction of advanced nuclear power plants.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DNA parts and gene constructs for plant biodesign

Plant biodesign requires the knowledge of DNA parts (e.g., genes, promoters, terminators), along with their combinations (as gene constructs) linked to engineered traits. DNA parts with validated or predicted functions in plants have been deposited in various online databases. However, these existing databases focus on basic biological functions of individual DNA parts, leaving a gap between basic knowledge and bioengineering applications. To fill this knowledge gap, we have created a user-friendly, open-ended database as a knowledge graph linking DNA parts to gene constructs to traits. This database contains experimentally validated DNA parts and gene constructs documented in peer-reviewed publications. The DNA parts include 1) molecular components with biological functions, such as genes involved in various biological processes (e.g., metabolic and signal transduction pathways) and 2) molecular components with technical functions, such as gene expression, genome engineering and sequence splicing. The gene constructs deposited in this database include both single-gene and multi-gene constructs. This database allows users to submit DNA parts and gene construct compositions linked to engineered traits described in peer-reviewed publications, providing a public digital repository for sharing the biodesign information among the researchers in the fields of plant biotechnology and plant synthetic biology.

plant biodesign synthetic biology gene constructs ↗

Lunar Base Construction Planning

Previous lunar missions and campaigns have been restricted to using robotic landers and lunar orbiting satellites as well as sortie type of operations using astronaut crews(NASA Apollo program).Now, the next phase of lunar exploration has begun under NASA’s Artemis program and there has been an international response where other nations such as China, Russia, India, Canada, Japan and theEuropean Union of nations, have all expressed interest in either collaborating or competing with NASA on theMoon. This next phase has an overarching goal of achieving a permanent human presence on theMoon via sustainable methods. A lunar base with human occupancy will require infrastructure to provide shelter, utilities, landing/launch pads, roads, communications, power and all the other necessities to sustain human life and protect equipment.Since human biology is not well suited for surviving in the lunar environment, there will be many forms of automated equipment, autonomy and robotic helpers that will minimize the amount of Extra-Vehicular Activity(EVA) required by the crew. This will mean that the radiation dosage received by the crew will stay within acceptable and safe career doses. Radiation shielding via the use of regolith can also mitigate radiation dangers.The required infrastructure must be constructed, but the mass and logistics of bringing all the construction materials from Earth are prohibitive, which makes the necessary construction difficult to achieve.In-Situ Resource Utilization (ISRU) aims to solve this challenge by sourcing construction materials locally or “in-situ”. This means that their transportation can be completely eliminated, resulting in large cost savings by avoiding the launch out of Earth’s deep gravity well and subsequent trans lunar injection, lunar orbit capture and landing. This paper will give ahistorical review and current status of lunar construction planning and a high level introduction to the required infrastructure and construction equipment that will be required to robotically build a lunar base using in-situ resources.It will also organize these tasks into logical groupings so that technology development and implementation can be pursued within a framework that can be referenced by all involved.

Lunar↗

Integrating Energy Efficiency Strategies with Industrialized Construction for Our Clean Energy Future: Preprint

NREL’s Industrialized Construction Innovation Team has developed an ambitious plan to accelerate the integration of energy efficiency (EE) strategies with Industrialized Construction (IC). The United States (U.S.) construction industry is beginning to use IC methods to build multifamily apartment buildings to address affordability and labor shortages. Apart from reducing cost of construction and delivery times, the IC method of permanent modular construction has the potential to facilitate the integration of a wide range of EE strategies and advanced controls into such buildings. While there may be unintended EE benefits to IC such as a tighter envelope due to higher construction quality, the process has not been leveraged specifically to enhance EE. NREL aims to claim this missed opportunity and integrate IC benefits with EE as well as advanced controls, distributed energy resources, and grid-friendly design strategies. The paper proposes an ‘IC Assessment Framework’ to achieve affordable zero-energy modular multifamily buildings. Through the selection criteria of Design for Manufacturing and Assembly, the framework aims to distill a broad range of proven EE strategies for site-built into a set of strategies that qualify as easy to integrate for off-site. The output is a Factory Information Model (FIM) that represents a process-based digital twin to enable advanced time-and-motion study, plugs into open source building energy modeling platform (EnergyPlus), and serves as a vital tool facilitating wider adoption of EE integration. Conclusively, the paper delineates next steps for upcoming pilots with NREL’s IC partners towards developing a transformational pathway for our Clean Energy Future.

30 DIRECT ENERGY CONVERSION↗

ADVANCED CONSTRUCTION TECHNOLOGY INITIATIVE (ACTI)

Advanced reactor technologies have attracted considerable financial support, catalyzing innovation in the nuclear energy landscape. These next generation reactors are designed with enhanced passive safety systems and the potential for cost reductions. As these advanced reactors approach technological maturity, their commercial success also requires focused examination and essential support. Economic assessments in the nuclear energy sector often emphasize construction costs and the risk of scheduling delays as primary contributors to deployment expenditures. Traditionally, vital elements of nuclear energy deployment including civil/structural engineering, design sophistication and automation have been either undervalued or postponed in the development cycles. Additionally, the nuclear industry’s collective experience in nuclear project execution has diminished over the past several decades due to the infrequency of new plant constructions. Hence, The National Reactor Innovation Center’s (NRIC) Advanced Construction Technology Initiative (ACTI) program aims to reduce cost overruns and schedule slippages that have plagued the construction of nuclear power plant projects. With this initiative, NRIC is facilitating the development of advanced nuclear plant construction technologies and approaches through partnerships that would provide game-changing benefits to the construction of advanced nuclear power plants.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Direct interpolative construction of the discrete Fourier transform as a matrix product operator

The quantum Fourier transform (QFT), which can be viewed as a reindexing of the discrete Fourier transform (DFT), has been shown to be compressible as a low-rank matrix product operator (MPO) or quantized tensor train (QTT) operator. However, the original proof of this fact does not furnish a construction of the MPO with a guaranteed error bound. Meanwhile, the existing practical construction of this MPO, based on the compression of a quantum circuit, is not as efficient as possible. We present a simple closed-form construction of the QFT MPO using the interpolative decomposition, with guaranteed near-optimal compression error for a given rank. This construction can speed up the application of the QFT and the DFT, respectively, in quantum circuit simulations and QTT applications. We also connect our interpolative construction to the approximate quantum Fourier transform (AQFT) by demonstrating that the AQFT can be viewed as an MPO constructed using a different interpolation scheme.

97 MATHEMATICS AND COMPUTING↗

Vision and Development of a Design, Implementation, and Verification Automation (DIVA) Software Platform for DNA Construction

Abstract DNA construction, while a prerequisite to many biological endeavors, is often a time-consuming distraction from an individual’s primary research objectives. We envisioned that with the right software infrastructure and cultural mindset, a single person could execute in parallel the batched DNA construction tasks of an entire research institute, at scales realizing efficiency gains through process and laboratory automation. In pursuit of this vision, we developed the Design, Implementation, and Verification Automation (DIVA) software platform. DIVA’s web interface enables researchers to design DNA constructs (using visual biological computer-aided design tools and biological parts repositories), submit designs for construction to dedicated staff, and track DNA construction as it progresses. DIVA supports the dedicated staff through the DNA construction process and records both successful and unsuccessful attempts toward improving the overall process. The platform is publicly available at public-diva.jbei.org and its open-source code through github.com/JBEI/DIVA.

Plahar, Hector [DOE Agile BioFoundry , , ,; DOE Jo↗

Universal construction of black hole microstates

We refine and extend a recent construction of sets of black hole microstates with semiclassical interiors that span a Hilbert space of dimension e S , where S is the black hole entropy. We elaborate on the definition and properties of microstates in statistical and black hole mechanics. The gravitational description of microstates employs matter shells in the interior of the black hole, and we argue that in the limit where the shells are very heavy, the construction acquires universal validity. To this end, we show it for very wide classes of black holes; we first extend the construction to rotating and charged black holes, including extremal and near-extremal solutions, with or without supersymmetry, and we sketch how the construction of microstates can be embedded in string theory. We then describe how the approach can include general quantum corrections, near or far from extremality. For supersymmetric black holes, the microstates we construct differ from other recent constructions in that the interior excitations are not confined within the near-extremal throat. Published by the American Physical Society 2024

Astronomy & Astrophysics↗

Draft ASME Boiler and Pressure Vessel Code Cases and Technical Bases for Use of Alloy 617 for Constructions of Nuclear Component Under Section III, Division 5

The American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code currently only allows five materials for use in construction of nuclear components for high temperature service. These are: 2.25Cr-1Mo and V-modified 9Cr-1Mo steels, Types 304 and 316 stainless steels and the high nickel Alloy 800H. Since 2005, the US high temperature gas-cooled reactor program has been characterizing elevated temperature mechanical properties of Alloy 617 as the leading candidate construction material for the intermediate heat exchanger. After analysis of these experimental results, along with historical data and additional results available through the Generation IV International Forum, Very High Temperature Reactor, Materials Program Management Board Materials Handbook, a draft ASME Code Case to allow nuclear construction with Alloy 617 for temperatures up to 1750°F (954°C) has been developed. This report contains the Code Case for Low Temperature Service Construction of Section III, Division 5, Subsection HB, Subpart A, Class A and Subsection HC, Subpart A, Class B components, which has been approved in Section II, Materials, and Section III, Rules for Construction of Nuclear Facility Components. Supporting technical justification for the low temperature Code Case is also included. This Code Case allows use of Alloy 617 up to 800°F (425°C). This report also contains an updated draft of a Section III, Division 5, Subsection HB, Subpart B, Class A Code Case for Alloy 617 to qualify it for use in construction of nuclear components up to 1750°F (954°C) for service life up to 100,000 hours. The draft contained in Appendix 4, subject to editorial revision and approval by the ASME Special Task Group on Alloy 617 Code Qualification, will be submitted for approval by letter ballot by the appropriate ASME Committees. The technical justification supporting the Code Case is presented in Appendix 5 of this report. This background document is part of the information package that will be submitted with the Code Case for ballot.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Development of National New Construction Weighting Factors for the Commercial Building Prototype Analyses (2008-2022)

The U.S. Department of Energy (DOE) tasked Pacific Northwest National Laboratory (PNNL) with updating commercial building construction weights for the purpose of estimating national and state-by-state energy savings impacts of changes made to various commercial energy codes and standards. A similar activity was last completed by PNNL in 2020 using disaggregate construction volume data acquired from the Dodge Data & Analytics database (formerly McGraw Hill) for the years 2003-2018 (Lei et al, 2020). As time passes, changes in economic and social demand reshape construction volume trends. For the current update, PNNL reviewed the same data source with the latest construction data for the years 2008-2022. For commercial building analyses, PNNL typically uses a suite of 16 prototype buildings simulated in the 19 ASHRAE climate zones with 16 of them present in the United States. The 2008-2022 commercial building weighting factors were derived using the same approach employed to develop the 2003-2018 set (Lei et al, 2020). Applying the construction volume data from the database to the prototypes and climate zones resulted in the following new construction area-based weighting factors. Table ES.1 shows the weighting factors including all building categories found in the database, and Table ES.2 shows the weighting factors normalized to include only buildings represented by the 16 prototypes. Section 3.0 also includes national- and state-level weighting factors by area and building count.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Orbital construction demonstration study

A conceptual design and program plan for an Orbital Construction Demonstration Article (OCDA) was developed that can be used for evaluating and establishing practical large structural assembly operations. A flight plan for initial placement and continued utility is presented as a basic for an entirely new shuttle payload line-item having great future potential benefit for space applications. The OCDA is a three-axis stabilized platform in low-earth orbit with many structural nodals for mounting large construction and fabrication equipments. This equipment would be used to explore methods for constructing the large structures for future missions. The OCDA would be supported at regular intervals by the shuttle. Construction experiments and consumables resupply are performed during shuttle visit periods. A 250 kw solar array provides sufficient power to support the shuttle while attached to the OCDA and to run construction experiments at the same time. Wide band communications with a Telemetry and Data Relay Satellite compatible high gain antenna can be used between shuttle revisits to perform remote controlled, TV assisted construction experiments.

Source record↗

Satellite Power System. Concept development and evaluation program, volume 6: Construction and operations

The construction, operation, and maintenance requirements for a solar power satellite, including the space and ground systems, are reviewed. The basic construction guidelines are explained, and construction location options are discussed. The space construction tasks, equipment, and base configurations are discussed together with the operations required to place a solar power satellite in geosynchronous orbit. A rectenna construction technique is explained, and operation with the grid is defined. Maintenance requirements are summarized for the entire system. Key technology issues required for solar power satellite construction operations are defined.

Benson, H.↗