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
Ceramics sintered using a MGS slurry system employing classic pottery (potter’s wheel), slip casting, material extrusion (robocasting/direct ink writing), 3D printing (layerwise slurry deposition with binder jetting) and as a reference dry pressing. Credits: David Karl et al.*
Development of the methods for in situ resource utilization on Mars requires validation ahead of time. Making durable and useful ceramics is one such material processing technique that would be valuable. In a paper just posted on the arXiv preprint server to be published in the journal Open Ceramics, David Karl at the Technische Universitaet Berlin and others* present findings on a study of such methods using Mars global simulants (MGS) as a proxy for clay on the Red Planet. These simulants, provided by Kevin Cannon’s Center for Asteroid and Lunar Surface Science (CLASS) Exolith Lab at the University of Central Florida, deliver superior strength when compared to other ISRU materials, as mentioned in a recent Tweet by Cannon.
The paper also documents the results of a sophisticated additive manufacturing technique called layerwise slurry deposition (LSD) using the MGS. As mentioned in the paper’s Introduction, “To highlight the importance of clay as a medium for human civilizations and thought (along with illustrating the usefulness of the unfired/fired concept, as cuneiform tablets are found in unfired as well as fired state), cuneiform tablets from 3D scans were reproduced as inspirational artifacts, illustrating the excellent LSD printing resolution”.
(Top left) Flowchart of MGS slurry production (described in detail in [5]), (top right) schematic of 2 the layerwise slurry deposition and (bottom) processing path for cuneiform tablets from 3D scans of 3 original cuneiform tablets made during the Ur III period (ca. 2100-2000 BC), produced as technological 4 demonstrators for LSD and inspirational artifacts for Mars colonization. Credits: David Karl et al.*
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* D. Karl, F. Kamutzki, P. Lima, A. Gili, T. Duminy, A. Zocca, J. Günster,A. Gurlo, Sintering of ceramics for clay in situ resource utilization on Mars, Open Ceramics, https://doi.org/10.1016/j.oceram.2020.100008.
