In-Situ Additive Construction in Space: 3D Printing Habitats for - - PowerPoint PPT Presentation

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In-Situ Additive Construction in Space: 3D Printing Habitats for - - PowerPoint PPT Presentation

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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.

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SLIDE 1 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

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SLIDE 2

Introduction

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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

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SLIDE 3

Multiple Sheltering Aspects are Needed on the Moon

Radiation Protection Thermal Protection Exhaust Plume Protection Micro-meteoroid Protection

Radiation Protection Thermal Protection Exhaust Plume Protection Micro- meteoroid Protection

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SLIDE 4

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Man-made Caves in Cappadocia, Turkey

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SLIDE 5

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Dome structures using Sand Bags

Nader Khalili

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SLIDE 6

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Roger Dean House

http://gallery.rogerdean.com/

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SLIDE 7

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Roger Dean House

http://gallery.rogerdean.com/

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SLIDE 8

Lava = Basalt

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SLIDE 9

Roman Basalt Construction

2nd Century Roman Basalt Construction: These structures have withstood the elements for thousands

  • f years!
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SLIDE 10

Lunar Regolith Definition

Regolith: Surficial 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.

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SLIDE 11

APOLLO 12 APOLLO 16

Basalt Granular Material = Construction Material

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SLIDE 12

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Promise of Additive Manufacturing

“Additive manufacturing will be a $5.2B industry by 2020” - Terry Wohlers

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SLIDE 13

Planetary Surface Construction Tasks

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Launch/Landing Pads Beacon/Navigation Aids Lighting Systems Communications Antenna Towers Blast Protection Berms Perimeter Pad Access & Utility Roads Spacecraft Refueling Infrastructure Power Systems Radiation, Thermal & Micro Meteorite Shielding Ablative Regolith Atmospheric Entry Heat Shields Radiation Shielding for Fission Power Plants Electrical Cable/ Utilities Trenches Foundations / Leveling Trenches for Habitat & Element Burial Regolith Shielding on Roof over Trenches Equipment Shelters Maintenance Hangars Dust free zones Thermal Wadi’s for night time Radiation shielding panels for spacecraft Regolith Mining for O2 Production H2O Ice/Regolith Mining from Shadowed Craters

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SLIDE 14

Foundation or Landing/Launch Pad 2D Additive Construction Using In-Situ Materials (Basalt)

Construct a 2D Planar Surface Landing Pad – In Situ Regolith (Tephra)

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SLIDE 15

3D Additive Construction Element Using In-Situ Materials (Basalt)

Needs a Caption

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Construction Location Flexibility

Multi-axis print head Curved wall tool path development Images Courtesy

  • f Dr. B. Khoshnevis,

Contour Crafting, LLC

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SLIDE 16

3D Additive Construction Element Using In-Situ Materials (Basalt)

Needs a Caption

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Environmental Protection

Complex Tool Path Development Allows Interior Walls Images Courtesy

  • f Dr. B. Khoshnevis,

Contour Crafting, LLC

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SLIDE 17

Additive Construction with Mobile Emplacement (ACME)

Rendering courtesy of Behnaz Farahi and Connor Wingfield

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)

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SLIDE 18

Additive Construction with Mobile Emplacement (ACME)

Rendering courtesy of Behnaz Farahi and Connor Wingfield

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
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SLIDE 19

Additive Construction with Mobile Emplacement (ACME)

Rendering courtesy of Behnaz Farahi and Connor Wingfield

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

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SLIDE 20

Additive Construction with Mobile Emplacement (ACME)

Rendering courtesy of Behnaz Farahi and Connor Wingfield

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SLIDE 21

Additive Construction with Mobile Emplacement (ACME)

Rendering courtesy of Behnaz Farahi and Connor Wingfield

Robotic Construction of a Foundation / Landing Pad Hilo, Hawaii

Robotic Grading Robotic Compaction Robotic Paver Laying

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SLIDE 22

Tele-operated Regolith Excavation

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Regolith Advanced Surface Systems Operations Robot (RASSOR ) 2.0

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SLIDE 23

Additive Construction with Mobile Emplacement (ACME)

Rendering courtesy of Behnaz Farahi and Connor Wingfield

Robotic Construction of a Foundation / Landing Pad Hilo, Hawaii

Robotic Paver Laying

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SLIDE 24

Hot Fire Test

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10’ x 10’ Test Pad: 100 Pavers Morpheus Class Rocket Thrust

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SLIDE 25

Dry Goods Delivery System

Rendering courtesy of Behnaz Farahi and Connor Wingfield

Automated Dispensing of Gravel, Coarse Sand, Fine Sand & Cements

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SLIDE 26

Liquid Goods Delivery System

Rendering courtesy of Behnaz Farahi and Connor Wingfield

Automated Dispensing of Water & Additives

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SLIDE 27

Robotic Gantry Positioning Mechanism

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SLIDE 28

Robotic Gantry Positioning Mechanism

Rendering courtesy of Behnaz Farahi and Connor Wingfield

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SLIDE 29

Completed 3D Printed Barracks “B-Hut”

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32’ L x 16’ W x 8.5’ H

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SLIDE 30

Additive Construction with Mobile Emplacement (ACME)

Rendering courtesy of Behnaz Farahi and Connor Wingfield

https://www.youtube.com/watch?v=LjBS6b7ZeF8

Video available online

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SLIDE 31

Centennial Challenge: 3D Print a Habitat

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Slide show of CC concepts $2.5 Million Prize Money

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SLIDE 32

Entries Finalists

Centennial Challenge: 3D Print a Habitat

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SLIDE 33
  • 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

MISSION REQUIREMENTS

Design Brief

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SLIDE 34

Phase 1: Winners

1st Place 2nd Place 3rd Place $25,000 Prize $15,000 Prize https://www.youtube.com/watch?v=HfvDIX7Gtvk

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SLIDE 35

Phase 2: Structural Member Competition

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Slide show of CC concepts

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SLIDE 36

Entries

Qualified

Finalists

Phase 2 Structural Member Competition

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SLIDE 37

Phase 2: Structural Member Competition

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Slide show of CC concepts

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SLIDE 38

Phase 2: Structural Member Competition

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Slide show of CC concepts

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SLIDE 39

Phase 2: 3D Print a 1.5 m Diameter Dome

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Slide show of CC concepts

Foster & Partners | Branch Tech 1st Place $250,000 Prize Polymer | Basalt Concrete Penn State University 2nd Place $150,000 Prize Metakaolin | Basalt Concrete

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SLIDE 40

Foster & Partners | Branch Tech 1st Place

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SLIDE 41

F+P | Branch Technologies Video

https://youtu.be/riYvNbPXIKc

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SLIDE 42

Coming Soon….Oct. 2017

Prize Purse of $1.4 million You are invited!

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.

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SLIDE 43

Imagine: 3D Printed Sydney Opera House

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https://i.pinimg.com/originals/25/47/39/254739fed47f9d9b3e21c9c02650c72a.jpg

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SLIDE 44

http://www.swinburne.edu.au/news/latest- news/2017/08/innovative-approach-to-3d-concrete- printing-recognised.php

3D Printed Sydney Opera House – Geo Polymers

Centre for Sustainable Infrastructure at Swinburne University of Technology, Victoria, Australia

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SLIDE 45

Imagine what could be possible

45 http://worldarchitecture.org/authors-links/pmcnn/sand-babel-solar-powered-twisting-skyscrapers-3d-printed-with-desert-sands.html

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SLIDE 46

Freedom for Architects

46 https://www.mydesy.com/3d-printed-tower