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ICON awarded $57 Million by NASA to develop lunar 3D printing technology for lunar surface construction

Conceptual illustration of Olympus, a lunar construction system based on in situ resource utilization. Credits: ICON

In a press release, the Austin based company reports how the Phase III award under NASA’s Small Business Innovation Research (SBIR) program will be used to adapt its existing additive manufacturing process for home building on Earth to the Olympus system using lunar regolith for fabrication of structures on the Moon. ICON envisions the system to be integrated into a rover that will be delivered to the Moon via a lander. The rover will then autonomously drive to a target site where the Olympus laser 3D printer will process lunar regolith into useful structures. The system can be used for fabricating roads, landing pads and habitats out of local resources without having to bring building materials from Earth, thereby significantly lowering costs. Once the system is proven on the Moon, perhaps in the later stages of Artemis, the same technology can be applied on Mars as well.

ICON plans to test the system “…via a lunar gravity simulation flight” although no details were revealed on such a mission. Presumably, this would be a parabolic flight in the Earth’s atmosphere. The company would use samples of lunar soil brought back during the Apollo missions and lunar regolith simulant to tune the process variables of their laser 3D printing equipment operating under these conditions. Once optimized, Olympus would be placed on the Moon “…to establish the critical infrastructure necessary for a sustainable lunar economy including, eventually, longer term lunar habitation.”

“The final deliverable of this contract will be humanity’s first construction on another world, and that is going to be a pretty special achievement.”

– Jason Ballard, ICON co-founder and CEO

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Self-replicating “living” machines for lunar settlement

Conceptual illustration of a self-replicating machine. Source: Wikipedia

In a 2020 paper in the journal Biomimetics, Alex Ellery who heads the Space Exploration Engineering Group in the Department of Mechanical & Aerospace Engineering at Carleton University, Ottawa, lays out a case for engineering mechanical systems that emulate biological life in the same vain as a Von Neumann universal constructor. This concept, conceived by the Hungarian-American mathematician John von Neumann in 1940s prior to the invention of the computer, is a machine that can make copies of itself given a set of instructions, sufficient materials and a source of energy.

Ellery begins by examining theories on the origin of life on Earth to distill down the essence of how inanimate material was transformed into living systems. He then goes on to define the basic characteristics of how organisms use energy to process materials to evolve and reproduce. Applying these principles to mechanical systems he envisions bioinspired machines be used to propagate self-replicating factories on the Moon in a lunar industrial ecology. Materials mined in situ by robots would be processed using solar energy via automated additive manufacturing processes analogous to living organisms reproducing to expand the facility.

“Adopting the notion of a biological ecosystem, we can envisage a modest self-sustained metabolism.”

In an examination of what life is, Ellery makes the analogy between ribosomes, the basic macromolecular machine that performs protein synthesis in living cells, and a 3D printer called the Replicating Rapid Prototyper (or RepRap), a key element of his research. Through additive manufacturing this device can print some of its own plastic components.

RepRap 3D printer comprising a Cartesian robot with extruder head (Figure 2 in the paper) capable of printing copies of some of its own plastic components.. Credits: Alex Ellery

Eventually, Ellery’s goal is for the device to be able to fabricate most of its own parts including the metal components. However, a fully autonomous self-replicating machine will required considerable advancements in artificial intelligence and automation. Initially, prefabricated complex components such as electronic circuitry, actuators, and sensors may be supplied independently as “vitamins” from Earth and assembled automatically during fabrication to enable automatic manufacture of the robots. Ellery introduces his team and describes his research at Carlton University in this short video.

Self-replicating factories designed for the production of space settlement infrastructure have been covered previously by SSP. Hybrid approaches that include humans in the loop to guide the process may be a near term solution until AI and robotic technologies become fully autonomous.

Some have postulated that if Von Neumann probes have been used by alien civilizations to colonize the galaxy there may be ways to detect them.

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Converting orbital trash to treasure with CisLunar Industries’ Micro Space Foundry

Illustration of orbital debris recycling. Instead of deorbiting after a few missions, debris removal spacecraft can refuel themselves with metal propellant using the Micro Space Foundry extending the lifespan and lowering costs. Credits: CisLunar Industries

CisLunar Industries is developing an innovative way to clean up Earth orbit by recycling spent rocket stages and other orbital debris using their Micro Space Foundry (MSF). In a March 2 presentation to the Future In-Space Operations telecon, CisLunar CEO Gary Calnan described the technology and markets for the MSF, development of which was funded by an SBIR/STTR grant from NASA. There is a vast untapped value chain of metals high above our heads. Over the last 60 years as satellites have been launched into space, the used upper stages have been cluttering up low Earth orbit and beyond. But the trash has value because it is useful material in orbit that has already incurred the launch cost.

The system works by robotically cutting aluminum feedstock off of derelict satellites and then processing the metal through the MSF using electromagnetic levitation furnace technologies originally proven on the ISS for virtually contactless metal recycling and reuse in a weightless environment. The MSF spits out rods of “fuel” to feed a Neumann Thruster on the debris removal spacecraft, which can then be powered to deorbit the target satellite and move on to its next destination. Rinse and repeat. The architecture has the potential to change the economics of the cislunar economy by harvesting a valuable in situ resource while cleaning up Earth orbit at the same time.

The Neumann Thruster, invented by Dr. Patrick “Paddy” Neumann, is an electric propulsion system for in-space use which is a highly adjustable, efficient and scalable method for moving satellites where they are needed. The Neumann Drive uses solid metal propellant and electricity to produce thrust via a pulsed cathodic arc system analogous to an arc welder. Neumann, who created the company Neumann Space to commercialize his invention, explains the physics behind the thruster in a video of an early prototype.

CisLunar Industries has other applications planned for the MSF in an emerging in-space ecosystem. In addition to extruding metallic rods as propellant, the system can fabricate long tubes for large-scale space structures or wires for additive manufacturing enabling an in-space commodities value chain and creating demand for processed metals.

Conceptual illustration of the MSF core processing unit, utilizing a modular design to enable lower cost flexible deployment and multiple products in an emerging cislunar economy. Credits: CisLunar Industries

So how mature is the technology? CisLunar has already demonstrated component validation in the lab taking the system to TRL 4. You can see a video documenting the experiment at timestamp 35:54 here. A parabolic flight to run an experiment in simulated weightlessness is scheduled for later this year. Actual in-space end-to-end demonstration with a Neumann Thruster is planned in 2024 via an agreement with Australian space services company Skykraft.

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Self replicating factories for space settlement

Artist’s illustration of a self replicating factory near an asteroid and serviced by a SpaceX Starship. Credits: Michel Lamontagne / Principium

The technology of self replicating machines has been gradually progressing toward maturity over the last few decades. The Space Studies Institute recognized this key enabler of space settlement as far back as the 1980s and covered the topic frequently in its newsletter updates. Now Michel Lamontagne has provided a status update in the latest issue of Principium. On page 50, he highlights the history of self replicating factories, provides a vision for the evolution of the concept for production of space settlement infrastructure and gives a summary of recent developments in key areas of research such as additive manufacturing, machine learning and cheap access to space that will be enablers of this space based industry.

The first factory will be built on the Moon after deep learning simulations prove the concept on Earth. Eventually the more autonomous versions would migrate to Mars and then to what may be the best suited location, the asteroid belt which “…may be the ultimate resource for space settlement construction.” Lamontagne believes “These factories would then follow humanity to the Stars, after having helped to build the infrastructure required for the occupation of the solar system and for Interstellar travel.”

Artist’s rendering of an early self replicating factory on the Moon with SpaceX Starships serving as basic construction elements. Credits: Michel Lamontagne / Principium
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Project MOONRISE demonstrates 3D printed regolith structures under lunar gravity conditions

Artist impression of the MOONRISE laser mounted on a lunar rover for fabrication of structures on the Moon. Credits: Laser Zentrum Hannover / 3D Printing Industry

A German company called Laser Zentrum Hannover .eV in partnership with the Technical University of Braunschweig has been working on a project called MOONRISE which aims to use laser technology to build a village on the Moon out of lunar regolith. Toward that end, the team for the first time has demonstrated the ability to 3D print structures out of simulated lunar regolith under lunar gravity conditions. The results of their experiments are described in an article in 3D Printing Industry.

The research was carried out in the Leibniz University Hannover’s Einstein-Elevator, a large-scale drop tower device in which experiments can be run under variable gravity conditions at a high repetition rate.

Initiated in 2019, Project MOONRISE is funded by the Volkswagen Foundation and is focused on improving the technology readiness level of additive manufacturing using lunar regolith as building material.

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Martian in situ manufacturing using chitosan biolith

Illustration of three applications of chitosan derived Martian biolith cast into different geometries including a wrench, freeformed material or an additive manufactured habitat model. Credits: Ng Shiwei, Stylianos Dritsas, Javier G. Fernandez via PLOS ONE

Working with simple chemistry suitable for an early Martian settlement, a team of researchers in Singapore has demonstrated that Martian biolith using chitosan derived from shrimp, with minimal energy requirements, could be used for rapid manufacturing of objects ranging from basic tools to rigid shelters. Ng Shiwei, Stylianos Dritsas, and Javier G. Fernandez publish their results in a paper in PLOS ONE.

Chitosan is chemically derived from chitin, the organic matrix produced by biological organisms incorporating calcium carbonate into rigid structures. Chitin would be a byproduct of food production in a closed-loop life support system on Mars.

Chitosan can form transparent objects similar in appearance and mechanical properties to plastic, which would be lacking in early stage Mars settlements. When processed with Martian regolith, the resulting Chitosan biolith produces a material with good mechanical properties and general utility for manufacturing on Mars.

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Redwire manufactures the first 3D printed ceramic in space

Image of Ceramics Manufacturing Module (CMM), a commercial manufacturing facility that produces ceramic parts in microgravity for terrestrial use. Credits: Redwire/Made in Space

Made in Space, a recent acquisition of Redwire, has just for the first time successfully manufactured a ceramic part in their Ceramics Manufacturing Module on the ISS using additive manufacturing. The demonstration could stimulate demand in low Earth orbit from terrestrial markets which will be a key driver for space industrialization. Redwire claims that the parts, which included a turbine blisk (bladed disk) and other test pieces, demonstrate that the CMM can produce ceramic parts that exceed the quality of turbine components made on Earth.

According to Redwire’s press release: “CMM aims to demonstrate that ceramic manufacturing in microgravity could enable temperature-resistant, reinforced ceramic parts with better performance, including higher strength and lower residual stress. For high-performance applications such as turbines, nuclear plants, or internal combustion engines, even small strength improvements can yield years-to-decades of superior service life.”

Image of CCM 3D printed part fabricated in LEO. Credits: Redwire
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Making oxygen from moondust with ROXY (and improving life on Earth)

Artist’s rendition of Airbus lunar lander with ROXY on board. Credits: Airbus

In a breakthrough experiment last month, a team led by Airbus Defence and Space (Friedrichshafen, Germany) has for the first time produced oxygen and other metals from simulated lunar soil with a proprietary process called Regolith to OXYgen and Metals Conversion, or ROXY. The revolutionary new process could be the core of an ISRU value chain on the moon, providing oxygen for habitats or rocket fuel, with added byproducts of metals and alloys as feedstock for additive manufacturing of building materials. This would significantly reduce the cost of settlements on the Moon as the construction materials could be fabricated in situ, without the need to be brought from Earth. Check out Airbus’ animation of ROXY here.

Airbus thinks that the ROXY reactor could have beneficial environmentally friendly applications on Earth as well:

“On Earth, ROXY opens a new pathway to drastically reduce the emissions of greenhouse gases that result from production of metals.” Since the process is essentially free of emissions “…these environmental impacts could be reduced, providing a significant contribution to the UN sustainability goals – another example of how space technologies can improve life on Earth”

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Project RegoLight: Solar sintering lunar soil for 3D printed settlements on the Moon

RegoLight mobile printing head as implemented. Credits: RegoLight Consortium / Space Applications Services / International Astronautical Federation

Project RegoLight was an in situ resource utilization program funded by the European Commission to study automation of a process using solar energy to heat lunar soil to form building elements for a lunar settlement. The project ran from 2016 – 2018 and was intended to raise the technology readiness level from 3 to 5. The conclusions of the project were presented at the 69th International Astronautical Congress (IAC) held in Bremen, Germany in October 2018 and summarized in a report available on Academia.edu.

RegoLight had several primary objectives including automation of additive manufacturing of building elements under ambient conditions, fabrication of larger structures with a mobile printing head, demonstration of solar sintering under vacuum conditions, production of building elements using simulated lunar soil, material characterization of the building elements and other related processes in the context of a lunar settlement architecture. These activities would support plans for the Moon Village.

Conceptual view of an operational lunar base. Credits: RegoLight Consortium / LIQUIFER Systems Group / International Astronautical Federation
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Lava Hive: ISRU Mars habitat

Stepwise illustration of the casting process to produce the Lava Hive; (1) deposition of foundation base, (2) regolith is gathered and sintered into a flow channel, (3) molten basalt from the sand/regolith is poured into the channel and allowed to solidify, (4) the next layer of regolith is spread across, and another channel sintered, (5) layer by layer the structure is constructed, (6) loose, un-sintered regolith is excavated from the structure, revealing the completed dome. Credits Aidan Cowley, et al.*

In a paper posted on Academia.edu, the 3rd prize winner for the 2015 NASA 3D Printed Mars Habitat Centennial Challenge called Lava Hive is described by a team* of European researchers. The habitat is produced by additive manufacturing via a ‘lava-casting’ construction technique and utilizing recycled spacecraft structures. Innovations include ‘re-use’ of discarded landing vehicles as part of the central habitat, 3D printed adjacent structures connected to the central habitat and use of a novel ‘LavaCast’ process to fabricate solid structures resistant to radiation and thermal cycling.

Illustration of the Lava Hive. The central habitat core is shown with the smaller 3D printed satellite structures clustered around it. Credits: René Waclavicek, LIQUIFER Systems Group, 2015

The Lava Hive Mars settlement has a number of advantages including a modular design with the ability to expand or adapt to changing mission requirements while “living off the land” with a simple ISRU process utilizing Martian soil, thereby reducing the amount of mass that would need to be launched from Earth.

* Authors of this paper are: Aidan Cowley, Barbara Imhof, Leo Teeney, René Waclavicek, Francesco Spina, Alberto Canals, Juergen Schleppi, Pablo Lopez Soriano