Results for “In-Situ Resource Utilization”

NASA NTRS1990

In-situ resource utilization in the design of advanced lunar facilities

Resource utilization will play an important role in the establishment and support of a permanently manned lunar base. At the University of Houston - College of Architecture and the Sasakawa International Center for Space Architecture, a study team recently investigated the potential use of lunar in-situ materials in the design of lunar facilities. The team identified seven potential lunar construction materials; concrete, sulfur concrete, cast basalt, sintered basalt, glass, fiberglass, and metals. Analysis and evaluation of these materials with respect to their physical properties, processes, energy requirements, resource efficiency, and overall advantages and disadvantages lead to the selection of basalt materials as the more likely construction material for initial use on a lunar base. Basalt materials can be formed out of in-situ lunar regolith, with minor material beneficiation, by a simple process of heating and controlled cooling. The team then conceptualized a construction system that combines lunar regolith sintering and casting to make pressurized structures out of lunar resources. The design uses a machine that simultaneously excavates and sinters the lunar regolith to create a cylindrical hole, which is then enclosed with cast basalt slabs, allowing the volume to be pressurized for use as a living or work environment. Cylinder depths of up to 4 to 6 m in the lunar mare or 10 to 12 m in the lunar highlands are possible. Advantages of this construction system include maximum resource utilization, relatively large habitable volumes, interior flexibility, and minimal construction equipment needs. Conclusions of this study indicate that there is significant potential for the use of basalt, a lunar resource derived construction material, as a low cost alternative to Earth-based materials. It remains to be determined when in lunar base phasing this construction method should be implemented.

Source record↗

NASA NTRS1992

In-situ resource utilization activities at the NASA Space Engineering Research Center

The paper describes theoretical and experimental research activities at the NASA Space Engineering Research Center aimed at realizing significant cost savings in space missions through the use of locally available resources. The fundamental strategy involves idea generation, scientific screening, feasibility demonstrations, small-scale process plant design, extensive testing, scale-up to realistic production rates, associated controls, and 'packaging', while maintaining sufficient flexibility to respond to national needs in terms of specific applications. Aside from training, the principal activities at the Center include development of a quantitative figure-of-merit to quickly assess the overall mission impact of individual components that constantly change with advancing technologies, extensive tests on a single-cell test bed to produce oxygen from carbon dioxide, and the use of this spent stream to produce methane.

Ramohalli, Kumar↗

NASA NTRS1991

In-Situ Resource Utilization (ISRU): Surface systems program area of the exploration technology program

The topics presented are covered in viewgraph form and include the following: (1) utilization of Lunar and Mars resources; (2) oxygen - an example of cost savings; (3) In Space Resource Utilization (ISRU); (4) basic resource processing methods; (5) planetary mining; (6) raw materials preparation; (7) validation, testbeds, and flight experiments; (8) mission readiness schedule; and (9) ISRU budget guideline.

Mckay, David S.↗

NASA NTRSDate not supplied

Bosch Carbon Catalyst Regeneration in Water II: Analysis of Bosch Catalyst Beads Throughout the Initial Regeneration Process

Catalyst integrity is an important factor in reactor longevity since it changes the effectiveness of a reaction. A Carbon Formation Reactor (CFR), used within Series Bosch (S-Bosch), utilizes an iron alloy catalyst to convert carbon monoxide and hydrogen into water and solid carbon. The catalyst promotes the formation of carbon to such an extent that pressure-causing clogs form within the reactor and reaction sites on the catalyst become limited. To remove carbon from both the reactor and the surface of the iron alloy catalyst, a technique was developed that utilizes water, an In-Situ Resource Utilization (ISRU) Resource, and agitation to regenerate the reactor. To ascertain catalyst integrity throughout this regenerative process, sample catalyst beads were taken before and after the carbon formation reaction, and then after the regeneration process. Additionally, wastewater from the regeneration process was sampled. The sampled beads and wastewater were observed under a Scanning Electron Microscopy (SEM) microscope and the beads were chemically etched to determine if the catalyst had degraded at any point during this process, and if catalyst was lost. Minimal catalyst degradation was observed after carbon formation in the CFR.

regeneration↗

NASA NTRSDate not supplied

Bosch Carbon Catalyst Regeneration in Water II: Analysis of Bosch Catalyst Beads Throughout the Initial Regeneration Process

Catalyst integrity is an important factor in reactor longevity since it changes the effectiveness of a reaction. A Carbon Formation Reactor (CFR), used within Series Bosch (S-Bosch), utilizes an iron alloy catalyst to convert carbon monoxide and hydrogen into water and solid carbon. The catalyst promotes the formation of carbon to such an extent that pressure-causing clogs form within the reactor and reaction sites on the catalyst become limited. To remove carbon from both the reactor and the surface of the iron alloy catalyst, a technique was developed that utilizes water, an In-Situ Resource Utilization (ISRU) Resource, and agitation to regenerate the reactor. To ascertain catalyst integrity throughout this regenerative process, sample catalyst beads were taken before and after the carbon formation reaction, and then after the regeneration process. Additionally, wastewater from the regeneration process was sampled. The sampled beads and wastewater were observed under a Scanning Electron Microscopy (SEM) microscope and the beads were chemically etched to determine if the catalyst had degraded at any point during this process, and if catalyst was lost. Minimal catalyst degradation was observed after carbon formation in the CFR.

Series Bosch↗

NASA NTRS1991

Options for Martian propellant production

A quantitative evaluation methodology for utilizing in-situ resources on Mars for the production of useful substances. The emphasis is on the chemical processes. Various options considering different feedstock (mostly, carbon dioxide, water, and iron oxides) are carefully examined for the product mix and the energy needs. Oxygen, carbon monoxide, alcohols, and other chemicals are the end products. The chemical processes involve electrolysis, methanation, and variations. It is shown that maximizing the product utility is more important than the production of oxygen, methane, or alcohols. An important factor is the storage of the chemicals produced. The product utility is dependent, to some extent, upon the mission. A combination of the stability, the enthalpy of formation, and the mass fraction of the products is seen to yield a fairly good quantitative feel for the overall utility and maximum mission impact.

Dowler, Warren↗

NASA NTRS2026

Prototype Demonstration of Solar Carbothermal System to Extract Oxygen from Regolith

The Carbothermal Reduction Demonstration (CaRD) project was an effort to develop a prototype system to demonstrate the extraction of oxygen from simulated lunar regolith using concentrated solar energy and a carbothermal reaction. The prototype consisted of a deployable solar concentrator capable of tracking the sun, carbothermal reactor, fluid system, gas analysis, and a solar concentrator control system consisting of avionics and software. These subsystems were developed by multiple NASA centers and a private industry partner, Sierra Space. The various teams worked together to define requirements and interfaces to successfully assemble the complex system and demonstrate an integrated solar carbothermal process. The solar concentrator developed at Glenn Research Center (GRC) was designed to be stowed for a launch environment then deployed on the lunar surface. It utilized a crossed dragone configuration of composite mirrors to direct horizontal sunlight onto a target 90° from the incoming sunlight. The key performance parameters for the solar concentrator were efficiency and power density. The carbothermal reactor was developed by Sierra Space through a separate project called the Carbothermal Oxygen Production Reactor (COPR) where it successfully demonstrated a fully automated process in a thermal vacuum environment. The fluid system needed for the carbothermal reaction was also developed by Sierra Space and successfully demonstrated in the same thermal vacuum test. The gas analysis system was developed at Kennedy Space Center (KSC) and was required to determine the amount of oxygen extracted during each test. The gas analysis system was based on the Mass Spectrometer Observing Lunar Operations (MSOLO) instrument. Avionics and software for the CaRD prototype were also developed at KSC and based on experience with MSOLO avionics and software. The control system was designed to stow, deploy, track the sun, and perform beam alignment of the concentrated light. The prototype subsystems were integrated and tested at Johnson Space Center’s (JSC) Energy Systems Test Area. A heliostat was used to direct sunlight toward the prototype in a way that is representative of the sunlight conditions at the south pole of the Moon. When concentrated sunlight was focused on simulated lunar regolith within the reactor, the gas analysis team confirmed the presence of carbon monoxide gas, which confirmed that a solar carbothermal reaction took place. The key performance parameter for the integrated prototype was grams of oxygen extracted per kilowatt hour of energy arriving at the concentrator primary mirror. The prototype design successfully demonstrated end-to-end capability and further steps to achieve a flight capable system have been defined. With lunar data, engineers would be able to design a scaled-up system capable of extracting oxygen from regolith at useful quantities for crew life support and rocket propellant. On the long term, this method of In-Situ Resource Utilization could be used to drastically reduce the cost and risk of a sustained human presence on the Moon by reducing the amount of oxygen that would have to be delivered.

Aaron Paz↗

NASA NTRS2026

Prototype Demonstration of an Integrated Solar Concentrator System and Carbothermal Reactor Using Solar Energy to Extract Oxygen from Regolith

The Carbothermal Reduction Demonstration (CaRD) project was an effort to develop a prototype system to demonstrate the extraction of oxygen from simulated lunar regolith using concentrated solar energy and a carbothermal reaction. The prototype consisted of a deployable solar concentrator capable of tracking the sun, carbothermal reactor, fluid system, gas analysis, and a solar concentrator control system consisting of avionics and software. These subsystems were developed by multiple NASA centers and a private industry partner, Sierra Space. The various teams worked together to define requirements and interfaces to successfully assemble the complex system and demonstrate an integrated solar carbothermal process. The solar concentrator developed at Glenn Research Center (GRC) was designed to be stowed for a launch environment then deployed on the lunar surface. It utilized a crossed dragone configuration of composite mirrors to direct horizontal sunlight onto a target 90° from the incoming sunlight. The key performance parameters for the solar concentrator were efficiency and power density. The carbothermal reactor was developed by Sierra Space through a separate project called the Carbothermal Oxygen Production Reactor (COPR) where it successfully demonstrated a fully automated process in a thermal vacuum environment. The fluid system needed for the carbothermal reaction was also developed by Sierra Space and successfully demonstrated in the same thermal vacuum test. The gas analysis system was developed at Kennedy Space Center (KSC) and was required to determine the amount of oxygen extracted during each test. The gas analysis system was based on the Mass Spectrometer Observing Lunar Operations (MSOLO) instrument. Avionics and software for the CaRD prototype were also developed at KSC and based on experience with MSOLO avionics and software. The control system was designed to stow, deploy, track the sun, and perform beam alignment of the concentrated light. The prototype subsystems were integrated and tested at Johnson Space Center’s (JSC) Energy Systems Test Area. A heliostat was used to direct sunlight toward the prototype in a way that is representative of the sunlight conditions at the south pole of the Moon. When concentrated sunlight was focused on simulated lunar regolith within the reactor, the gas analysis team confirmed the presence of carbon monoxide gas, which confirmed that a solar carbothermal reaction took place. The key performance parameter for the integrated prototype was grams of oxygen extracted per kilowatt hour of energy arriving at the concentrator primary mirror. The prototype design successfully demonstrated end-to-end capability and further steps to achieve a flight capable system have been defined. With lunar data, engineers would be able to design a scaled-up system capable of extracting oxygen from regolith at useful quantities for crew life support and rocket propellant. On the long term, this method of In-Situ Resource Utilization could be used to drastically reduce the cost and risk of a sustained human presence on the Moon by reducing the amount of oxygen that would have to be delivered.

Oxygen from Regolith↗

NASA NTRS2026

Prototype Demonstration of Solar-Carbothermal System to Extract Oxygen From Regolith

The Carbothermal Reduction Demonstration (CaRD) project was an effort to develop a prototype system to demonstrate the extraction of oxygen from simulated lunar regolith using concentrated solar energy and a carbothermal reaction. The prototype consisted of a deployable solar concentrator capable of tracking the sun, carbothermal reactor, fluid system, gas analysis, and a solar concentrator control system consisting of avionics and software. These subsystems were developed by multiple NASA centers and a private industry partner, Sierra Space. The various teams worked together to define requirements and interfaces to successfully assemble the complex system and demonstrate an integrated solar carbothermal process. The solar concentrator developed at Glenn Research Center (GRC) was designed to be stowed for a launch environment then deployed on the lunar surface. It utilized a crossed dragone configuration of composite mirrors to direct horizontal sunlight onto a target 90° from the incoming sunlight. The key performance parameters for the solar concentrator were efficiency and power density. The carbothermal reactor was developed by Sierra Space through a separate project called the Carbothermal Oxygen Production Reactor (COPR) where it successfully demonstrated a fully automated process in a thermal vacuum environment [1]. The fluid system needed for the carbothermal reaction was also developed by Sierra Space and successfully demonstrated in the same thermal vacuum test. The gas analysis system was developed at Kennedy Space Center (KSC) and was required to determine the amount of oxygen extracted during each test. The gas analysis system was based on the Mass Spectrometer Observing Lunar Operations (MSOLO) instrument. Avionics and software for the CaRD prototype were also developed at KSC and based on experience with MSOLO avionics and software. The control system was designed to stow, deploy, track the sun, and perform beam alignment of the concentrated light. The prototype subsystems were integrated and tested at Johnson Space Center’s (JSC) Energy Systems Test Area. A heliostat was used to direct sunlight toward the prototype in a way that is representative of the sunlight conditions at the south pole of the Moon. When concentrated sunlight was focused on simulated lunar regolith within the reactor, the gas analysis team confirmed the presence of carbon monoxide gas, which confirmed that a solar carbothermal reaction took place. The key performance parameter for the integrated prototype was grams of oxygen extracted per kilowatt hour of energy arriving at the concentrator primary mirror. The prototype design successfully demonstrated end-to-end capability and further steps to achieve a flight capable system have been defined. With lunar data, engineers would be able to design a scaled-up system capable of extracting oxygen from regolith at useful quantities for crew life support and rocket propellant. On the long term, this method of In-Situ Resource Utilization could be used to drastically reduce the cost and risk of a sustained human presence on the Moon by reducing the amount of oxygen that would have to be delivered.

Koorosh R Araghi↗

NASA NTRS1991

Development of a figure-of-merit for space missions

The concept of a quantitative figure-of-merit (FOM) to evaluate different and competing options for space missions is further developed. Over six hundred individual factors are considered. These range from mission orbital mechanics to in-situ resource utilization (ISRU/ISMU) plants. The program utilizes a commercial software package for synthesis and visual display; the details are completely developed in-house. Historical FOM's are derived for successful space missions such as the Surveyor, Voyager, Apollo, etc. A cost FOM is also mentioned. The bulk of this work is devoted to one specific example of Mars Sample Return (MSR). The program is flexible enough to accommodate a variety of evolving technologies. Initial results show that the FOM for sample return is a function of the mass returned to LEO, and that missions utilizing ISRU/ISMU are far more cost effective than those that rely on all earth-transported resources.

Preiss, Bruce↗

NASA NTRS1991

Primary igneous rocks on Mars: Composition and distribution

The present knowledge of the crustal composition of Mars is synthesized and implications discussed for in-situ resource utilization. Sources of information include remote sensing observations, Viking XRF chemical measurements, and characteristics of the SNC meteorites (which most researchers now believe originated on Mars). There are a number of lines of evidence that abundant ferrous-iron rich igneous crustal rocks (and derivative soils) are available at or very near the current Martian surface at many locations on the planet. Most of these exposures show spectroscopic evidence for abundant pyroxene, consistent with basaltic compositions. The SNC meteorites, which have basaltic compositions, were also studied extensively. Interpretations of Mars crustal chemistry and mineralogy (petrology) based on these various sources are reviewed, and their consistencies and differences are discussed.

Singer, Robert B.↗

NASA NTRS1991

Regenerative fuel cell architectures for lunar surface power

Power needs projected for the lunar and Mars exploration missions range from a few kilowatts for initial manned outposts and rovers to hundreds of kilowatts for permanent bases and in-situ resource utilization. The 354 hour lunar night presents a formidable challenge in energy storage systems for non-nuclear power systems. The Photovoltaic/Regenerative Fuel Cell (PV/RFC) power system is currently being considered as an option to meet the initial low power requirements. For lunar applications, the RFC mass can be a critical driver in the overall PV/RFC system mass. For the long duration nighttime operation missions, the hydrogen/oxygen (H2/O2) reactants and storage are the dominant components from a mass standpoint. It is important, therefore, to examine options which may reduce the reactant and storage mass and, thereby, result in mass savings for the overall PV/RFC system. Various RFC configurations for the stationary lunar missions has been examined using Rocketdyne's RFC computer model. For the stationary applications, a GaAs/Ge PV array with a 3000 psi gas storage proton exchange membrane (PEM) RFC providing 25 kWe during the day and 12.5 kWe at night was designed. PV/RFC systems utilizing super-critical H2/O2 storage and Cryogenic H2/O2 storage for the RFCs were then compared with the baseline high pressure gas storage RFC system. Preliminary results indicate that for long duration nighttime operation missions, the super-critical H2/O2 storage RFC systems offer over 20% mass advantage over the high pressure gas storage while the mass savings for the cryogenic H2/O2 storage RFC systems can be as high as 30%.

D W Harris↗

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 NTRS2026

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

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

Kingsley Yeboah Gyabaah↗

NASA NTRS1991

Technologies of ISRU/ISMU

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

Ramohalli, Kumar↗

NASA NTRSDate not supplied

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

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

In-situ resource utilization↗

NASA NTRS1988

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

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

Source record↗

NASA NTRS1988

Economical in-situ processing for orbital debris removal

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

Ramohalli, Kumar↗