Make It – Don’t Take It: NASA’s Vision for Extraterrestrial Manufacturing and Construction
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in space manufacturing↗
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Make It- Don't Take It: NASA's Vision for Extraterrestrial Manufacturing and Construction
Explore the source record for details and available documents.
In space Manufacturing↗
In Space Manufacturing and Extraterrestrial Construction
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In space manufacturing↗
On The Incorporation of Both Function-Driven Requirements and Topology Optimization in The Development of Lunar Launch & Landing Pads
In the design of additively manufactured structures, there can be a constant battle between focusing on function-driven design and topology optimization in an attempt to improve a products ability to meet all requirements. Function-driven optimization is defined as the process of identifying the best design parameters that satisfy project functionality requirements. Function-driven optimization is typically implemented by a designer(s) who, instead of computational limitations, has human bias for the input or inputs determined. On the other hand, topology optimization is defined as a mathematical method that optimizes material layout within a given design space, for a given set of loads, boundary conditions, and constraints with the goal of maximizing the performance of the system. In topology optimization, the work is defined by the limited mathematical inputs and computationally available goals/restraints. If not evaluated simultaneously, these two approaches can result in fundamentally different design concepts meant to address the same requirements. NASA’s Artemis program includes the development of a base camp near the lunar South Pole. After site selection is made, one of the first infrastructure elements needed will be a launch and landing pad (LLP). The construction of such a pad will prevent damage to nearby structures from plume-surface interaction (PSI) while also providing a stable platform for the lander. These benefits reduce the required distance between the established landing zones and other settlement infrastructure. In this paper, the authors evaluate the requirements associated with lunar LLP development, application of both functional and topological optimization techniques, methodologies to combine the two techniques, and potential impacts on final design of such a pad.
In-situ↗
Overview of NASA’s Break the Ice Lunar Challenge Phase 1
As NASA works to extend human exploration of the solar system, a sustained presence on the Moon will be critical for developing and testing the technologies and systems needed for future missions to Mars and beyond. In situ resource utilization (ISRU)—the use of lunar materials for life support, fuel, energy, manufacturing, and construction—is necessary to limit the delivery of supplies from Earth. One of the most important of these resources is water. Water supports all life on Earth and will be critical to supporting human exploration beyond Earth. On the Moon, water is trapped in icy regolith at the lunar poles, including inside permanently dark and cold craters. Novel approaches are needed to excavate the icy regolith and transport it for processing in support of permanent human missions on the Moon. To accelerate the development of such approaches and to seek diverse ideas, NASA’s Centennial Challenges launched the Break the Ice Lunar Challenge in November 2020. Phase 1 of the challenge was focused on stimulating innovative approaches for excavating icy regolith and delivering water in extreme lunar environmental conditions. The challenge sought to incentivize solutions for maximizing water delivery while minimizing energy use and the mass of equipment required to be transported to the lunar surface. Submissions for phase 1 of the challenge were due in June 2021 and winners were announced in August 2021. This paper provides details about the execution of the challenge, solutions received, criteria used to select winning solutions, and status of the phase 2 of the challenge.
Naveen Vetcha↗
Lunar utilization
The resources, techniques, and purposes to which lunar materials could be put are discussed, with attention given to transporting lunar materials to cislunar space for the construction of space manufacturing and habitable facilities. A model molecule, demandite, which represents the mole fraction of all materials used in the U.S. in 1967, is used to assess the lunar resources defined during Apollo missions. It is shown that duplication of the same manufacturing, fuel, and life-support systems in space as those on earth would cost several orders of magnitude more if the materials originated on earth than on the moon. The demandite would be sent into cislunar orbit using linear electric motors. Lunar surface concentrations of pyroxenes, olivine, feldspars, ilmenite, basalts, anorthostatic rocks, and breccias are reviewed, noting that carbon in the regolith is solar-wind derived, while in lunar rocks the carbon is indigenous. Lunar mining techniques are envisioned, especially the capacity to move large masses at 1/6 the effort required on the earth.
Waldron, R. D.↗
Space manufacturing III; Proceedings of the Fourth Conference, Princeton University, Princeton, N.J., May 14-17, 1979
Papers are presented on the various technological, political, economic, environmental and social aspects of large manufacturing facilities in space. Specific topics include the potential global market for satellite solar power stations in 2025, the electrostatic separation of lunar soil, methods for extraterrestrial materials processing, the socio-political status of efforts toward the development of space manufacturing facilities, the financing of space industrialization, the optimization of space manufacturing systems, the design and project status of Mass Driver Two, and the use of laser-boosted lighter-than-air-vehicles as heavy-lift launch vehicles. Attention is also given to systems integration in the development of controlled ecological life support systems, the design of a space manufacturing facility to use lunar materials, high performance solar sails, the environmental effects of the satellite power system reference design, the guidance, trajectory and capture of lunar materials ejected from the moon by mass driver, the relative design merits of zero-gravity and one-gravity space environments, consciousness alteration in space and the prospecting and retrieval of asteroids.
Grey, J.↗
Apollo experience report: Lunar module instrumentation subsystem
The design concepts and philosophies of the lunar module instrumentation subsystem are discussed along with manufacturing and systems integration. The experience gained from the program is discussed, and recommendations are made for making the subsystem more compatible and flexible in system usage. Characteristics of lunar module caution and warning circuits are presented.
Obrien, D. E., III↗
Lunar production of space photovoltaic arrays
The advantages of manufacturing solar cells for use in space on the moon rather than on Earth are discussed. It is shown how solar cells manufactured on the moon could significantly reduce the cost of transportation of power systems to space destinations, including the moon, Mars, earth orbit, and transfer orbits. Silicon is abundant on the moon, and refining processes are demonstrated which do not depend on extensive use of reactants imported from Earth. Because of the lower requirements for refined silicon, the amorphous silicon process is preferred, despite lower efficiencies. Calculations show that the specific power of amorphous silicon cells can be adequate for most uses.
Landis, Geoffrey A.↗
A Study of Layered Structural Configurations as Thermal and Impact Shielding of Lunar Habitats
The focus of this study is the analysis of a proposed multilayer material configuration as lunar habitat shielding so as to assess its ability to resist temperature extremes and impact. In order to resist this environmental hazard, the analysis will compare various configurations of potential shielding layers using both in-situ resource utilization (ISRU) and Earth-based materials. The technology for implementation of in-situ resources in construction is developing, though not yet able to produce a functional lunar habitat. As the lunar infrastructure is developed, ISRU techniques for manufacturing and construction may become more viable. Therefore, both types of materials are considered due to potential for application towards both near-term and long-term commencements of habitat construction. The thermal analysis in this paper utilizes the nonlinear heat equation to produce a depth-dependent temperature gradient from the habitat exterior to the interior that changes continuously with time during the lunar diurnal cycle. Static loading conditions meant to simulate the impact force of a 77.9 g meteorite were used to analyze the ability of a proposed multilayer shielding configuration to resist impact. A thermal stress analysis was performed to observe the effects of heat transfer through the proposed multilayer configuration. The results of this study should be useful in determining the potential for implementation of efficient shielding layers for the initial lunar base.
Layered systems↗
Space Resources Roundtable 2
Contents include following: Developing Technologies for Space Resource Utilization - Concept for a Planetary Engineering Research Institute. Results of a Conceptual Systems Analysis of Systems for 200 m Deep Sampling of the Martian Subsurface. The Role of Near-Earth Asteroids in Long-Term Platinum Supply. Core Drilling for Extra-Terrestrial Mining. Recommendations by the "LSP and Manufacturing" Group to the NSF-NASA Workshop on Autonomous Construction and Manufacturing for Space Electrical Power Systems. Plasma Processing of Lunar and Planetary Materials. Percussive Force Magnitude in Permafrost. Summary of the Issues Regarding the Martian Subsurface Explorer. A Costing Strategy for Manufacturing in Orbit Using Extraterrestrial Resources. Mine Planning for Asteroid Orebodies. Organic-based Dissolution of Silicates: A New Approach to Element Extraction from LunarRegohth. Historic Frontier Processes Active in Future Space-based Mineral Extraction. The Near-Earth Space Surveillance (NIESS) Mission: Discovery, Tracking, and Characterization of Asteroids, Comets, and Artificial Satellites with a microsatellite. Privatized Space Resource Property Ownership. The Fabrication of Silicon Solar Cells on the Moon Using In-Situ Resources. A New Strategy for Exploration Technology Development: The Human Exploration and Development of Space (HEDS) Exploratiori/Commercialization Technology Initiative. Space Resources for Space Tourism. Recovery of Volatiles from the Moon and Associated Issues. Preliminary Analysis of a Small Robot for Martian Regolith Excavation. The Registration of Space-based Property. Continuous Processing with Mars Gases. Drilling and Logging in Space; An Oil-Well Perspective. LORPEX for Power Surges: Drilling, Rock Crushing. An End-To-End Near-Earth Asteroid Resource Exploitation Plan. An Engineering and Cost Model for Human Space Settlement Architectures: Focus on Space Hotels and Moon/Mars Exploration. The Development and Realization of a Silicon-60-based Economy in CisLunar Space. Our Lunar Destiny: Creating a Lunar Economy. Cost-Effective Approaches to Lunar Passenger Transportation. Lunar Mineral Resources: Extraction and Application. Space Resources Development - The Link Between Human Exploration and the Long-term Commercialization of Space. Toward a More Comprehensive Evaluation of Space Information. Development of Metal Casting Molds by Sol-Gel Technology Using Planetary Resources. A New Concept in Planetary Exploration: ISRU with Power Bursts. Bold Space Ventures Require Fervent Public Support. Hot-pressed Iron from Lunar Soil. The Lunar Dust Problem: A Possible Remedy. Considerations on Use of Lunar Regolith in Lunar Constructions. Experimental Study on Water Production by Hydrogen Reduction of Lunar Soil Simulant in a Fixed Bed Reactor.
Ignatiev, A.↗
Hybrid Modeling Study on Grain Evolution in the Metal Welding Process and Its Potential Lunar Application
Metal is most commonly used structural material in a wide range of spacecraft, and welding is the principal method for joining metal components into functional systems. However, conducting welding experiments under extreme environments—such as microgravity or vacuum conditions in space—is prohibitively expensive and experimentally challenging. To overcome these limitations, multi-physics computational welding models provide a cost-effective and versatile alternative. In this work, the authors have developed a coupled thermal (fluid) microstructure simulation framework to model metal welding under varying gravity conditions. The framework integrates a mixed-mode heat transfer formulation (conduction, convection, and radiation) with molten pool fluid dynamics, enabling accurate prediction of temperature fields and weld-pool geometry. A grain growth model is further incorporated to capture the spatial and temporal evolution of microstructure, including grain size distribution and morphological transitions during solidification. This approach provides detailed insight into molten pool evolution and grain-level microstructure development throughout the welding process. By explicitly parameterizing environmental conditions, the model supports extrapolation to off-Earth manufacturing scenarios such as welding on the lunar surface. Tantalum—chosen in this study due to its high melting point, oxidation resistance, and mechanical stability at elevated temperatures—serves as the material system for model demonstration. Beyond Tantalum, the integrated multi-physics framework offers broad applicability for predictive welding simulations of various structural and refractory metals or alloys used in extreme terrestrial or extraterrestrial environments.
kinetic Monte Carlo (SPPARKS)↗
Initial Testing the Exploration Extravehicular Mobility Unit (xEMU) in Lunar Environment Simulation at the Neutral Buoyancy Lab (NBL) in 2022
Understanding how to effectively train for Extravehicular Activities (EVAs) for Artemis missions is critical. Tasked by the new Extravehicular Activity and Human Surface Mobility Program(EHP), a team of stakeholders from engineering and flight operations worked together to test the Exploration Extravehicular Mobility (xEMU) in the Neutral Buoyancy Lab(NBL) simulating the lunar environment. The NBL is a pool in which astronauts are typically trained to complete simulated International Space Station (ISS) EVA tasks in a neutral weigh-out. The overall focus for this test series was evaluating how well the NBL could be used as an effective simulated environment for Artemis lunar EVAs. New NBL support hardware was manufactured to support this test series and update the interfaces to be more representative of xEMU hardware such as a new NBL Portable Life Support System(PLSS)mock-up and umbilical, lights and cameras, and display and control unit (DCU).To simulate the 1/6th-gravity (1/6-g) environment, extra weights were added around the suit to create an accurate center of gravity representation. The Partial Gravity Weigh-out Stand (PGWS) predicted where and how much weight would be required for the 1/6th-G simulation and predicted the center of gravity placement. After the weigh-out attempt was completed, the suited participant would complete a set of directed tasks such as kneeling, object pick-up, and walking to evaluate the weigh-out. To create the lunar environment, sand, boulders, and ramps were added to the pool floor. If time allowed after weigh-out was determined acceptable, the flight operations team would direct the suited participants to complete simulated Artemis EVA tasks using flight-like tools and tool cart. The team also evaluated turning out the overhead lights in the NBL for a portion of some of the test runs and using a solar simulator to create amore realistic lunar south pole lighting environment. The test series completed one unmanned test and nine manned tests. With four of the tests, dual xEMU suited operations were completed with subjects in both the small and large xEMU sizes. Overall, the NBL was able to create an acceptable lunar landscape and ability to have two subjects work side by side in pressurized xEMUs which currently cannot be achieved in other test environments. Achieving a stable 1/6th-G lunar weigh-out and clear, consistent dual suit communications was a challenge for this series. Future work is planned to continue to improve this simulation environment.
spacesuit↗
Initial Testing of the Exploration Extravehicular Mobility Unit (xEMU) in Lunar Environment Simulation at the Neutral Buoyancy Lab (NBL) in 2022
Understanding how to effectively train for Extravehicular Activities (EVAs) for Artemis missions is critical. Tasked by the new Extravehicular Activity and Human Surface Mobility Program(EHP), a team of stakeholders from engineering and flight operations worked together to test the Exploration Extravehicular Mobility (xEMU) in the Neutral Buoyancy Lab(NBL) simulating the lunar environment. The NBL is a pool in which astronauts are typically trained to complete simulated International Space Station (ISS) EVA tasks in a neutral weigh-out. The overall focus for this test series was evaluating how well the NBL could be used as an effective simulated environment for Artemis lunar EVAs. New NBL support hardware was manufactured to support this test series and update the interfaces to be more representative of xEMU hardware such as a new NBL Portable Life Support System(PLSS)mock-up and umbilical, lights and cameras, and display and control unit (DCU).To simulate the 1/6th-gravity (1/6-g) environment, extra weights were added around the suit to create an accurate center of gravity representation. The Partial Gravity Weigh-out Stand (PGWS) predicted where and how much weight would be required for the 1/6th-G simulation and predicted the center of gravity placement. After the weigh-out attempt was completed, the suited participant would complete a set of directed tasks such as kneeling, object pick-up, and walking to evaluate the weigh-out. To create the lunar environment, sand, boulders, and ramps were added to the pool floor. If time allowed after weigh-out was determined acceptable, the flight operations team would direct the suited participants to complete simulated Artemis EVA tasks using flight-like tools and tool cart. The team also evaluated turning out the overhead lights in the NBL for a portion of some of the test runs and using a solar simulator to create amore realistic lunar south pole lighting environment. The test series completed one unmanned test and nine manned tests. With four of the tests, dual xEMU suited operations were completed with subjects in both the small and large xEMU sizes. Overall, the NBL was able to create an acceptable lunar landscape and ability to have two subjects work side by side in pressurized xEMUs which currently cannot be achieved in other test environments. Achieving a stable 1/6th-G lunar weigh-out and clear, consistent dual suit communications was a challenge for this series. Future work is planned to continue to improve this simulation environment.
spacesuit↗
LEM electronics reliability.
Lunar Excursion Module /LEM/ reliability program, discussing engineering, manufacturing and techniques of design and qualification testing of electronic components
QUALITY CONTROL↗
Apollo Program Summary Report: Synopsis of the Apollo Program Activities and Technology for Lunar Exploration
Overall program activities and the technology developed to accomplish lunar exploration are discussed. A summary of the flights conducted over an 11-year period is presented along with specific aspects of the overall program, including lunar science, vehicle development and performance, lunar module development program, spacecraft development testing, flight crew summary, mission operations, biomedical data, spacecraft manufacturing and testing, launch site facilities, equipment, and prelaunch operations, and the lunar receiving laboratory. Appendixes provide data on each of the Apollo missions, mission type designations, spacecraft weights, records achieved by Apollo crewmen, vehicle histories, and a listing of anomalous hardware conditions noted during each flight beginning with Apollo 4.
Source record↗
Lunar Thermal Wadis and Exploration Rovers: Outpost Productivity and Participatory Exploration
The presentation introduces the concept of a thermal wadi, an engineered source of thermal energy that can be created using native material on the moon or elsewhere to store solar energy for use by various lunar surface assets to survive the extremely cold environment of the lunar night. A principal benefit of this approach to energy storage is the low mass requirement for transportation from Earth derived from the use of the lunar soil, or regolith, as the energy storage medium. The presentation includes a summary of the results of a feasibility study involving the numerical modeling of the performance of a thermal wadi including a manufactured thermal mass, a solar energy reflector, a nighttime thermal energy reflector and a lunar surface rover. The feasibility study shows that sufficient thermal energy can be stored using unconcentrated solar flux to keep a lunar surface rover sufficiently warm throughout a 354 hour lunar night at the lunar equator, and that similar approaches can be used to sustain surface assets during shorter dark periods that occur at the lunar poles. The presentation includes descriptions of a compact lunar rover concept that could be used to manufacture a thermal wadi and could alternatively be used to conduct a variety of high-value tasks on the lunar surface. Such rovers can be produced more easily because the capability for surviving the lunar night is offloaded to the thermal wadi infrastructure. The presentation also includes several concepts for operational scenarios that could be implemented on the moon using the thermal wadi and compact rover concepts in which multiple affordable rovers, operated by multiple terrestrial organizations, can conduct resource prospecting and human exploration site preparation tasks.
Sacksteder, Kurt↗
The economics of bootstrapping space industries - Development of an analytic computer model
A simple economic model of 'bootstrapping' industrial growth in space and on the Moon is presented. An initial space manufacturing facility (SMF) is assumed to consume lunar materials to enlarge the productive capacity in space. After reaching a predetermined throughput, the enlarged SMF is devoted to products which generate revenue continuously in proportion to the accumulated output mass (such as space solar power stations). Present discounted value and physical estimates for the general factors of production (transport, capital efficiency, labor, etc.) are combined to explore optimum growth in terms of maximized discounted revenues. It is found that 'bootstrapping' reduces the fractional cost to a space industry of transport off-Earth, permits more efficient use of a given transport fleet. It is concluded that more attention should be given to structuring 'bootstrapping' scenarios in which 'learning while doing' can be more fully incorporated in program analysis.
Goldberg, A. H.↗