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Offworld’s Prospector 1 mission to demonstrate ISRU on the Moon

Concept illustration of Offworld’s Prospector 1 Mobile Excavator. Credits: Dallas Bienhoff / Offworld, Inc.

At the intersection of AI, swarm robotics and mining technology lies the key to sustainable, affordable space development. Offworld, Inc. is on the cutting edge of this frontier with their suite of diverse robot species that when coordinated with collective intelligence, will enable sustainable in situ resource utilization (ISRU) thereby lowering the cost of establishing settlements on the Moon and beyond, while kickstarting a thriving off Earth economy. In a presentation to the Future In-Space Operations (FISO) Telecon on July 24, Space Systems Architect Dallas Bienhoff described Offworld’s plans for an ambitious demonstration mission called Prospector 1.

In April 2023, OffWorld Europe entered into an agreement with the Luxembourg Space Agency to collaborate on a Lunar ISRU exploration program commissioned by the European Space Agency. The multi-year initiative will develop a processing system focused on harvesting and utilizing lunar ice resources. The program will develop a Lunar Processing Module (LPM) to be integrated into a mobile excavator that will be launched to Moon’s south pole on the Prospector 1 mission currently scheduled for late 2027. The goal of Prospector 1 is to demonstrate the capability of processing icy lunar regolith to produce oxygen and hydrogen. The LPM when loaded with icy regolith will process the lunar soil to extract water, then via electrolysis produce oxygen and hydrogen. The module’s hopper is designed to receive up to 50 kg of regolith and batch process 2.5kg/hour. The unit will be housed on a mobile excavator massed at 2500 kg. Offworld has already completed TRL4 testing on the LPM in their Luxembourg office.

Offworld is evaluating several suppliers for delivery of their payload to the Moon. These include Blue Origin’s Blue Moon Mark 1 Lander, Astrobotic’s Griffin, Intuitive Machines NOVA-D and the SpaceX Starship.

The company is exploring a variety of options for generation of power for the mission. Of course landers provide some minimal power but not nearly enough for processing lunar regolith. One promising system under consideration is the Vertical Solar Array Technology (VSAT) under development by Astorbotic which will provide 10kw of power (only in sunlight). But wait, there’s more! Astrobotic announced this month that they were just awarded a Small Business Innovation Research (SBIR) award by NASA to develop a larger version of the array called VSAT-XL capable of delivering 50kw. Designed to track the sun, VSAT is ideal for location at the lunar south pole where the sun’s rays are at very low elevation and provide semi-permanent illumination on the rims of permanently shadowed craters.

Comparison of relative sizes of the two VSAT solar arrays. Credit: Astrobotic

Another innovative alternative is a power source called the Nuclear Thermionic Avalanche Cell (NTAC ) under development by Tamer Space, a company providing a range of power and construction resources for settlements on the Moon, the Cislunar economy and sustainable pioneering of Mars. The device is an electrical generator that converts nuclear gamma-ray photons directly to electric power in a compact, reliable package with high power density capable of long-life operation without refueling. NTAC can provide higher power levels (e.g. starting at 100kw) and is not dependent on the sun to enable operations through the lunar night should Offworld elect to locate their facility far from the Moon’s poles or in permanently shadowed regions. Tamer described their technology at the 2023 Space Resources Roundtable

Image of a research prototype of the Nuclear Thermionic Avalanche Cell: Credit: Tamer Space

After Propector 1, Offworld’s follow on plans envision a second Prospector 2 to be launched in the 2029 timeframe. This mission will ramp up capability to include multiple robot species such as an excavator, hauler, and processor. In addition, liquefaction will be added to the process stream (not just gaseous products) and pilot plant capabilities will be demonstrated to reduce risk for the next mission. In 2031, a formal pilot plant will be established with multiple excavators and haulers. The facility will have a fixed processing plant and storage facilities capable of producing tons of water, oxygen, and hydrogen. By the end of 2034, OffWorld plans to launch an industrial scale ISRU plant with output of 100s of tons of volatiles, elements and bulk regolith per year.

Bienhoff said at the conclusion of his presentation that Offworld’s long term vision for lunar operations include: “Industrial scale ISRU, 10s – 100s of tons of product per year – by product [I mean] that’s processed regolith, that’s oxygen, that’s hydrogen, that’s water, that’s perhaps metals. We plan to monetize or use every gram we excavate. That’s a tall order, but in order to have a thriving lunar community, we need to produce as much as we can on the Moon, for the Moon, before we think about exporting from the Moon.”

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Lunar landing pad trade study

Artist’s impression of a lunar landing pad. Credits: SEArch+

When humanity returns to the Moon and begins to build infrastructure for permanent settlements, propulsive landings will present considerable risk because rocket plumes can accelerate lunar dust particles in the bare regolith to high velocities which could result in considerable damage to nearby structures. Obviously, nothing can be done about the first spacecraft that will return to the moon later this decade unless they use their own rocket plume to create a landing pad like the concept proposed in a NIAC Grant by Masten Space Systems (now part of Astrobotic).

Flight Alumina Spray Technique (FAST) instant landing pad deployment during lunar landing. Source: Matthew Kuhns, Masten Space Systems Inc (now Astrobotic)

Therefore, before significant operations can begin on the Moon that require lots of rockets, a high priority will be construction of landing pads to prevent sandblasting by rocket plume ejecta of planned structures such as habitats, science experiments and other equipment. Several methods are currently being studied. Some require high energy consumption. Others could take a long time to implement. Still others are technologically immature. Which technique makes the most economic sense? Phil Metzger and Greg Autry examine options for the best approach to this urgent need in a November 2022 paper in New Space.

A lunar landing pad should have an inner and outer zone. The inner zone will have to withstand the intense heat of a rocket plume during decent and ascent. The outer zone can be less robust as the expanding gases will cool rapidly and decrease in pressure but will still be expanding rapidly, so erosion will have to be mitigated over a wider area.

Landing pad layout showing inner and outer zone measurements proposed in this study (Figure 1 in paper). Credits: Philip Metzger and Greg Autry / New Space – Lunar surface image credit: NASA.

Several processes of fabricating landing pads were examined by the authors. Sintering of regolith is one such technique, where dust grains are heated and fused by a variety of methods including microwave heating or focused solar energy. SSP has reported on the latter previously, but in this study it was noted that that technology needs further development work. Fabricating pavers by baking in ovens in situ was also examined in a addition to infusion of a polymer into the regolith to promote particle adhesion.

An economic model was developed to support construction of landing pads for NASA’s Artemis Program based on experimental data and the physics for predicting critical features of construction methods. Factors such as the equipment energy consumption, the mass of microwave generators compared to the power output needed to sinter the soil to specified thickness, and the mass of polymer needed to infuse the regolith to fabricate the pads were included in the model. Other factors were considered including the costs associated with program delays, hardware development, transportation of equipment to the lunar surface, and reliability.

When varying these parameters and comparing different combinations of manufacturing techniques, the trade study optimized the mass of construction equipment to balance the costs of transportation with program delays. The authors found that from a cost perspective, microwave sintering makes the most sense for both the inner and outer regions of the landing pad, at least initially. When transportation costs come down to below a threshold of $110K/kg then a hybrid combination of microwave sintering in the inner zone and polymer infusion of regolith in the outer zone makes the most sense.

Once astronauts land safely and begin EVAs on the lunar surface, they can keep from tracking dust into their habitat by taking an electron beam shower.

Other lunar dust problems and their risks can be mitigated with solutions covered previously on SSP.