National Aeronautics and Space Administration In-Situ Additive Construction in Space: 3D Printing Habitats for Astronauts Off ‐ Earth Mining Forum Day 2, Session 1 University of New South Wales Sydney, Australia September 21, 2017 Robert P. Mueller NASA KSC Swamp Works
Introduction Rob Mueller Senior Technologist NASA Kennedy Space Center (KSC) Cape Canaveral, Florida, USA Co-Founder of the KSC Swamp Works – an innovation environment for technology Co-Founder of the Granular Mechanics & Regolith Operations (GMRO) lab Chairman of the ASCE Aerospace Division / 2016 Earth & Space conference BSME Bachelor of Science in Mechanical Engineering – University of Miami MSSE Master of Space Systems Engineering – TU Delft, Netherlands MBA Master of Business Administration – Florida Institute of Technology 28 years of NASA experience – from dust to thrust 2
Multiple Sheltering Aspects are Needed on the Moon Thermal Protection Micro- Exhaust Plume meteoroid Protection Protection Radiation Protection Micro-meteoroid Protection Radiation Protection Exhaust Plume Protection Thermal Protection
Man-made Caves in Cappadocia, Turkey 4
Dome structures using Sand Bags Nader Khalili 5
Roger Dean House http://gallery.rogerdean.com/ 6
Roger Dean House http://gallery.rogerdean.com/ 7
Lava = Basalt 8
Roman Basalt Construction 2nd Century Roman Basalt Construction: These structures have withstood the elements for thousands of years!
Lunar Regolith Definition Regolith : S urficial layer covering the entire lunar surface ranging in thickness from meters to tens of meters formed by impact process – physical desegregation of larger fragments into smaller ones over time.
Basalt Granular Material = Construction Material APOLLO 16 APOLLO 12
Promise of Additive Manufacturing “Additive manufacturing will be a $5.2B industry by 2020” - Terry Wohlers 12
Planetary Surface Construction Tasks Launch/Landing Pads Electrical Cable/ Utilities Trenches Beacon/Navigation Aids Foundations / Leveling Lighting Systems Trenches for Habitat & Element Burial Communications Antenna Towers Regolith Shielding on Roof over Trenches Blast Protection Berms Equipment Shelters Perimeter Pad Access & Utility Roads Maintenance Hangars Spacecraft Refueling Infrastructure Dust free zones Power Systems Thermal Wadi’s for night time Radiation, Thermal & Micro Meteorite Radiation shielding panels for spacecraft Shielding Regolith Mining for O 2 Production Ablative Regolith Atmospheric Entry Heat Shields H 2 O Ice/Regolith Mining from Shadowed Craters Radiation Shielding for Fission Power Plants 13
Foundation or Landing/Launch Pad 2D Additive Construction Using In-Situ Materials (Basalt) Construct a 2D Planar Surface Landing Pad – In Situ Regolith (Tephra)
3D Additive Construction Element Using In-Situ Materials (Basalt ) Needs a Caption Construction Location Flexibility Multi-axis print Curved wall tool path head development Images Courtesy of Dr. B. Khoshnevis, Contour Crafting, LLC 15
3D Additive Construction Element Using In-Situ Materials (Basalt) Needs a Caption Environmental Protection Images Courtesy of Dr. B. Khoshnevis, Contour Crafting, LLC Complex Tool Path Development Allows Interior Walls 16
Additive Construction with Mobile Emplacement (ACME) The ACME team consisted of the following members: • NASA Marshall Space Flight Center (MSFC) • NASA Kennedy Space Center (KSC) “Swamp Works” • USACE ERDC Construction Engineering Research Laboratory (CERL) • Contour Crafting Corp. (CC Corp.) • Pacific International Center for Exploration Systems (PISCES) Rendering courtesy of Behnaz Farahi and Connor Wingfield
Additive Construction with Mobile Emplacement (ACME) The USACE had the following objectives for construction of a Barracks B-hut in a forward base: • Reduce construction time from 4-5 days to 1 day per structure • Reduce construction personnel requirements from 8 to 3 per structure • Reduced logistics impacts associated with materials shipped, personnel, and resources to sustain the structures and personnel • Decrease material shipped from out of theater from 5 tons to less than 2.5 tons • Improved energy performance of the envelope from less than R1 to greater than R15 • Reduced sustainment (logistics) and operations/maintenance personnel • Reduce construction waste from 1 ton to less than 500 pounds • Improved security during construction • Improved local population acceptance by mimicking local construction Rendering courtesy of Behnaz Farahi and Connor Wingfield
Additive Construction with Mobile Emplacement (ACME) NASA had the following objectives for construction of a prototype habitat for feasibility and potential Astronaut crew training: • First demonstration of additive construction using planetary analog materials • Provide a detailed analysis of materials for additive construction on different planets, including radiation shielding potential • Advance the Technology Readiness Level (TRL) of additive construction hardware and processes to provide risk reduction and capabilities to future mission development programs • Provide the gateway to fabricating structures on demand in space with in-situ resources, reducing the need for sizeable structure up-mass • Provide a significant return on investment by enabling future NASA missions not feasible without the capability to manufacture structures in situ and doing so with significant external leverage • Provide a first step towards evolving additive construction for use on Deep Space Missions • Demonstrate tele-operations to reduce testing operations cost and show applicability to planetary surfaces • Rendering courtesy of Behnaz Farahi and Connor Wingfield
Additive Construction with Mobile Emplacement (ACME) Rendering courtesy of Behnaz Farahi and Connor Wingfield
Additive Construction with Mobile Emplacement (ACME) Robotic Construction of a Foundation / Landing Pad Hilo, Hawaii Robotic Grading Robotic Compaction Robotic Paver Laying Rendering courtesy of Behnaz Farahi and Connor Wingfield
Tele-operated Regolith Excavation Regolith Advanced Surface Systems Operations Robot (RASSOR ) 2.0 22
Additive Construction with Mobile Emplacement (ACME) Robotic Construction of a Foundation / Landing Pad Hilo, Hawaii Robotic Paver Laying Rendering courtesy of Behnaz Farahi and Connor Wingfield
Hot Fire Test Morpheus Class Rocket Thrust 10’ x 10’ Test Pad: 100 Pavers 24
Dry Goods Delivery System Automated Dispensing of Gravel, Coarse Sand, Fine Sand & Cements Rendering courtesy of Behnaz Farahi and Connor Wingfield
Liquid Goods Delivery System Automated Dispensing of Water & Additives Rendering courtesy of Behnaz Farahi and Connor Wingfield
Robotic Gantry Positioning Mechanism
Robotic Gantry Positioning Mechanism Rendering courtesy of Behnaz Farahi and Connor Wingfield
Completed 3D Printed Barracks “B-Hut” 32’ L x 16’ W x 8.5’ H 29
Additive Construction with Mobile Emplacement (ACME) Video available online https://www.youtube.com/watch?v=LjBS6b7ZeF8 Rendering courtesy of Behnaz Farahi and Connor Wingfield
Centennial Challenge: 3D Print a Habitat $2.5 Million Prize Money Slide show of CC concepts 31
Centennial Challenge: 3D Print a Habitat Entries Finalists
Design Brief M ISSION R EQUIREMENTS • Crew of four on a year long research mission to Mars in the year 2035 • Production of habitat using in-situ resources • 1000 ft² habitable space • Three 45 ft³ ECLSS systems
Phase 1: Winners 1 st Place 2nd Place $25,000 Prize $15,000 Prize 3rd Place https://www.youtube.com/watch?v=HfvDIX7Gtvk
Phase 2: Structural Member Competition Slide show of CC concepts 35
Phase 2 Structural Member Competition Entries Qualified Finalists
Phase 2: Structural Member Competition Slide show of CC concepts 37
Phase 2: Structural Member Competition Slide show of CC concepts 38
Phase 2: 3D Print a 1.5 m Diameter Dome Foster & Partners | Penn State University Branch Tech 2nd Place Slide show of CC concepts 1 st Place $150,000 Prize $250,000 Prize Metakaolin | Basalt Concrete Polymer | Basalt Concrete 39
Foster & Partners | Branch Tech 1 st Place
F+P | Branch Technologies Video https://youtu.be/riYvNbPXIKc
Phase 3: On-Site Habitat Competition Will focus on the 3D-Printing fabrication of a scaled habitat design, using indigenous materials combined with or without recyclables. Coming Soon….Oct. 2017 Prize Purse of $1.4 million You are invited!
Imagine: 3D Printed Sydney Opera House https://i.pinimg.com/originals/25/47/39/254739fed47f9d9b3e21c9c02650c72a.jpg 43
3D Printed Sydney Opera House – Geo Polymers Centre for Sustainable Infrastructure at Swinburne University of Technology, Victoria, Australia http://www.swinburne.edu.au/news/latest- news/2017/08/innovative-approach-to-3d-concrete- printing-recognised.php
Imagine what could be possible http://worldarchitecture.org/authors-links/pmcnn/sand-babel-solar-powered-twisting-skyscrapers-3d-printed-with-desert-sands.html 45
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