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TESSARAE for orbital biolabs and more

Conceptual illustration of an orbital biolab constructed using TESSERAE architecture. Credit: Aurelia Institute

At last year’s International Conference on Environmental Systems (ICES), Aurelia Institute Vice President of Engineering Annika Rollock presented a paper on development of an orbital TESSERAE habitat to conduct biotechnology research. TESSERAE (Tessellated Electromagnetic Space Structures for the Exploration of Reconfigurable, Adaptive Environments) covered previously on SSP, was conceived and developed by Ariel Ekblaw, cofounder and CEO of Aurelia as part of her doctoral thesis at MIT. A TED Talk by Ekblaw from last April provides more detail on the concept with footage of prototypes demonstrated in space on the International Space Station (ISS).

The paper “Development of a Flight-Scale TESSERAE Habitat Concept for Biotechnology Research Outpost Applications” by Rollock, Max Pommier, William J. O’Hara, and Ekblaw, presents preliminary findings from a case study on the TESSERAE habitat which aims to bridge traditional space station architectures with future-oriented, adaptive designs. Legacy space habitats, such as the ISS, rely on monolithic hulls or cylindrical modules constrained by launch vehicle fairings, limiting scalability and geometric flexibility. TESSERAE offers a departure from these norms by using flat-packed, tile-based modules that self-assemble in orbit to form a truncated icosahedron. This structure, commonly known as a “buckyball” sharing the same shape as the carbon molecule buckminsterfullerene (C60) named after architect and inventor R. Buckminster Fuller due to its resemblance to his geodesic dome designs, will enable larger volumes and novel configurations when connected together.

The authors provide more detail on the concept referencing a trade study presented at ICES 2023 by the Aurelia Institute, which reviewed historical and contemporary space architecture to identify gaps and opportunities. They underscore the need for habitats that are both innovative and grounded in proven engineering principles. The paper serves as a “dynamic snapshot” of the ongoing TESSERAE case study as of spring 2024, inviting collaboration rather than presenting a finalized design. It envisions a platform based on TESSERAE as a commercial biotechnology research outpost in Low Earth Orbit (LEO), aligning with NASA’s Commercial LEO Destinations (CLD) goals and the burgeoning market for microgravity-enabled research. The paper highlights subsystem analyses for environmental control, thermal management, and power, alongside novel interior layouts informed by user research and terrestrial architecture best practices.

The authors make the case that self-assembling structures like TESSERAE could revolutionize human spaceflight by enabling adaptive environments that support diverse crews, including non-professional astronauts. This is particularly timely as the ISS nears decommissioning in 2031, necessitating new orbital platforms for critical research with increasing involvement by private industry..

The mission overview lays out one possible operational vision for the 2030s: a TESSERAE microgravity platform sustaining human life, scientific inquiry with a biotechnology focus, and ancillary activities in LEO. Designed for a crew of four—two biotechnologists and two career astronauts—it features biotechnology applications, capitalizing on microgravity’s unique properties for protein crystallization and biologic medicines production.

Protein crystal growth in space yields superior quality due to reduced sedimentation and convection, facilitating precise structural data for drug discovery. The paper references applications in treating among other maladies, muscular dystrophy, breast cancer, and periodontal disease, citing decades of ISS-based experiments by pharmaceutical firms. Similarly, biologic medicines—proteins, enzymes, nucleic acids, and antibodies derived from natural sources—benefit from low-gravity acceleration in discovery and preclinical testing. The global biologics market is projected to reach over $700 billion by 2030, underscoring the potential economic upside. Innovations like Redwire’s seed-based crystal manufacturing and Varda’s in-orbit ritonavir production (an HIV antiviral) have demonstrated feasibility, with microgravity enabling bulk-free returns via seeds or small samples.

The concept of operations (ConOps) details a 32-tile assembly (20 hexagons, 12 pentagons, each 2.26 m edge length, 0.46 m thick), launched in a dispenser stacked aboard a SpaceX Falcon 9 launch vehicle. After dispensing out of the payload bay, orbital self-assembly employs electro-permanent magnets for bonding at the tile edges, forming a 493 m³ pressurized volume post-clamping and gasketing. Outfitting prioritizes autonomy: critical systems integrate into the tiles, with secondary elements (e.g., storage, mobility aids) added via robotics or minimal EVAs. After full systems checkout post-assembly, operations include 1–6 month crewed expeditions, cargo resupplies, and uncrewed intervals.

Comparative occupancy analysis positions TESSERAE favorably: at 123 m³ per person, it rivals the ISS (168 m³ for six) and Tiangong (113 m³ for three) emphasizing permanent quarters and lab space for its four-person upper limit, ensuring psychological and functional adequacy. This aligns with NASA’s CLD objectives, fostering commercial viability while accommodating “visiting scientists” alongside professionals.

With respect to interior concepts and design principles, TESSERAE’s non-cylindrical, open-central geometry introduces unique interior challenges and opportunities, diverging from conventional axial modules. The paper explores layouts tailored for diverse crews, drawing on user interviews (astronauts, analogue astronauts, scientists) and literature like Sharma et al.’s Astronaut Ethnography Project and Häuplik-Meusburger’s activity-based approach. Five core design principles and “desirements” guide this strategy: a human-centered approach accounting for bodily navigation and psychosocial needs; contextual affordances leveraging microgravity (e.g., multi-axis movement in open volumes); sensory mediation via lighting, acoustics, and airflow for zoned activities; accessibility with ample, clutter-free stowage; and a balance of permanence (fixed volumes) with flexibility (reconfigurable elements like folding partitions).

These principles inform environmental mediations for biotechnology: labs require vibration isolation and containment for experiments, while communal spaces mitigate isolation via views and biophilic design elements. The paper discusses layouts prioritizing flow, orientation, and adaptability. One configuration features a central “node” for socialization and exercise, ringed by radial spokes: private quarters, labs, hygiene nodes, and utility closets embedded in the shell. This exploits the buckyball’s symmetry for efficient use of space, with tethers and handrails guiding microgravity transit. Labs allocate ~100 m³ total, segmented for crystallization (vibration-dampened gloveboxes) and biologics (flow benches, incubators), in accordance with preliminary user needs.

Diagram (Figure 5 from paper) depicting four internal layout options, with key space dividers and elevation maps depicting the arrangement of functional areas on each external tile. Credits: Annika E. Rollock et al. / Aurelia Institute
Exploded view (Figure 6 from paper) of the Lofted layout option for the TESSERAE habitat. Credits: Annika E. Rollock et al. / Aurelia Institute

Sensory design mitigates monotony: variable LED lighting simulates diurnal cycles, acoustic panels dampen noise, and materiality ( e.g., fabric panels) enhances tactility. Stowage integrates nets and modular racks, addressing chronic ISS issues. Flexibility allows crew reconfiguration via magnetic mounts, supporting mission evolution. Hygiene and galley zones emphasize efficiency, with water-efficient fixtures tied to the Environmental Control and Life Support System (ECLSS). Overall, interiors blend spacecraft rigor with architectural humanism, fostering well-being for non-experts.

The authors provide a subsystem analysis discussing trades for ECLSS, thermal control, and power. ECLSS recommendations draw from ISS heritage leveraging NASA’s Carbon Dioxide Removal and Oxygen Generation Assemblies but adapt to TESSERAE’s modularity: distributed nodes per each individual tile reduce single-point failures, with regenerative loops for water and air.

Thermal management addresses the buckyball’s high surface-area-to-volume ratio, prone to radiative losses. Multi-layer insulation and variable-emittance coatings are proposed, integrated into tiles for passive control, supplemented by active radiators and heat exchangers. Finite element modeling was used to inform stress distribution across the tile seams.

Power generation leverages roll-out solar arrays deployed post-assembly, sized for 20–30 kW demands for the needs of the labs, ECLSS and other power systems. Trades evaluate photovoltaics vs. emerging tech, prioritizing launch mass. Batteries buffer eclipse periods, with guidance navigation integrated with attitude control via control gyroscopes, minimizing propellant use.

These analyses emphasize scalability: TESSERAE’s tiles enable redundant, upgradable subsystems, contrasting with legacy monolithic designs.

The paper identifies a few challenges. For instance, assembly reliability (magnet actuation in vacuum), pressurization integrity at seams, and outfitting logistics. But opportunities abound in biotech such as enabling “fly-your-own-experiment” for scientists, accelerating drug pipelines, and demonstrating adaptive habitats for lunar/Mars precursors. User research highlights psychosocial needs—privacy amid openness, sensory variety against confinement—which will inform iterative designs.

Future work matures hardware testing in microgravity (e.g., parabolic flights), refines trades via modeling, and pursues partnerships for CLD certification. The authors invite input, positioning TESSERAE as a collaborative pivot toward reconfigurable space living.

This case study encapsulates one of TESSERAE’s promises: a self-assembling, biotech-focused habitat merging innovation with pragmatism. By the 2030s, it could sustain crews in 493 m³ of adaptive volume in LEO, tapping into a $700B+ market while advancing human-centered space architecture. Preliminary insights from this work — from ConOps to design of interiors— lay the groundwork for transformative outposts that not only return benefits to human lives on Earth, but are preparing humanity to become a spacefaring species.

While the Aurelia Institute is a nonprofit organization, Ariel Ekblaw cofounded a startup called Rendezvous Robotics which aims to generate revenue building large-scale structures like antenna apertures, space solar power arrays and orbital data centers, all autonomously fabricated in space using TESSARAE. Rendezvous Robotics recently partnered with another startup called Starcloud which plans to fabricate gigawatt-scale orbital AI data centers using Ekblaw’s invention, a potentially huge new market forecasted to be just over the horizon by several tech leaders in the news recently. Blue Origin CEO Jeff Bezos just announced he’ll be leading a new AI company called Project Prometheus and says AI orbital data centers are coming in the next decade or two. Last May former Google chief executive Eric Schmidt acquired Relativity Space to put data centers in orbit. Earlier this month Elon Musk says in not more than 5 years, the lowest cost way to do AI compute, will be in space. And Mach33 Research, an investment research firm focused on the industrialization of space, predicts that orbital compute energy will be cheaper than on Earth by 2030. TESSARAE could be leveraged to assemble these space-based hyperscalers autonomously and quickly while proving out this reconfigurable technology which can be used to build large-scale adaptable habitats and other infrastructure in space for a multitude of applications. As stated on the their website,

“Aurelia is working toward geodesic dome habitats, microgravity concert halls, space cathedrals—the next generation of space architecture that will delight, inspire, and protect humanity for our future in the near, and far, reaches of space.”

Artist illustration of a habitat constructed from TESSARAE modules in Earth orbit. Credit: Aurelia Institute

Finally, in celebration of the 50th anniversary of the 1975 NASA Space Settlements: A Design Study, the Institute announced today they are sponsoring The Aurelia Institute Prize in Design for Space Urbanism. An award of up to $20,000 will granted for concepts of a functioning space station in one of three categories: A space station in LEO or at a Lagrange point; a space habitat in lunar orbit or on the surface of the Moon; or an automated industrial facility (e.g. focused on space mining, energy, biotech, etc.) in one of those locations.

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Sierra Space and payload integrator Tec-Masters to facilitate test of Honda’s Circulative Renewable Energy System on the ISS

Artist impression of Sierra Space’s Dream Chaser space plane Tenacity en route to the ISS. Credits: Sierra Space.

Honda is teaming up with Sierra Space and Tec-Masters to test their Circulative Renewable Energy System (CRES) designed to use water and sunlight to produce oxygen, hydrogen, and electricity for use on the Moon. The company’s research suggests that CRES could power a lunar colony, providing life support and fuel while recycling water in a closed-loop system from water sourced in situ.

Honda’s CRES is designed to support lunar activities by generating essential resources using sunlight and water extracted from lunar regolith or ice deposits, especially at the Moon’s polar regions. The system employs a high differential pressure water electrolysis process, which breaks down water into high-pressure hydrogen and oxygen. In a lunar colony, oxygen would be used for breathable air as well as stored in fuel cells to produce electricity, while the water byproduct is recycled back into the system, creating a closed-loop cycle. CRES is efficient, lightweight, and low-maintenance, ideal for settlements established in the harsh lunar environment, including extreme temperature fluctuations and low gravity. The system’s ability to operate under these conditions makes it suitable, potentially reducing reliance on Earth resupply and supporting a sustainable lunar presence.

Honda’s CRES is a sophisticated technology developed to support human activities on the Moon by leveraging local resources. It is part of a joint research effort with the Japan Aerospace Exploration Agency (JAXA), an international partner in NASA’s Artemis program, which seeks to establish a sustainable human presence on the Moon.

Circulative renewable energy system Honda is working to develop as part of the infrastructure for humanity’s sustained habitation on the Moon where resources other than sunlight and water are not available. Credits: JAXA / Honda

The core technology of CRES is a high differential pressure water electrolysis system, which electrolyzes water to produce high-pressure hydrogen and oxygen. Its is an evolution of Honda’s Power Creator technology, initially developed for fuel cell vehicles and hydrogen stations here on Earth, reflecting Honda’s broader commitment to carbon neutrality and sustainability.

Key technical specifications and advantages include:

  • Size and Weight: The electrolysis stack measures 420 mm tall and 210 mm wide, with the overall system at 980 mm tall, making it compact and lightweight, suitable for space transport where costs are approximately $700,000 per kilogram (delivered to the lunar surface).
  • Pressure Capability: It can store hydrogen at pressures up to 70 MPa, about 700 times Earth’s atmospheric pressure, enhancing storage efficiency.
  • Low Maintenance: The system requires no mechanical compressor, reducing complexity and maintenance needs in space.
  • Adaptability to Lunar Conditions: Engineered to withstand the Moon’s extreme environment, including temperature variations from 110°C during the day to -170°C at night, 1/6th Earth gravity, and high radiation levels.

Sierra Space, Honda, and Tec-Masters have formed a strategic partnership to test Honda’s high-differential pressure water electrolysis system on the International Space Station (ISS) facilitated be Sierra Space’s Dream Chaser spaceplane. Dream Chaser has a cargo capacity of over 6 tons and can return payloads to Earth at under 1.5g’s on commercial runways, enhancing its flexibility for space missions. The first Dream Chaser, named Tenacity, is currently undergoing final testing at NASA’s Kennedy Space Center for its ISS mission under NASA’s Commercial Resupply Services-2 (CRS-2) contract. The launch is currently planned for no earlier than the third quarter of this year, however, this first payload will not include Honda’s water electrolysis system. It has not been disclosed which upcoming Dream Chaser mission will transport the system to the ISS.

This testing aims to validate the system’s performance in space prior to operations on the Moon. Sierra Space will manage the mission, working with the Center for the Advancement of Science in Space (CASIS) and NASA, while Tec-Masters will handle payload integration, leveraging their extensive ISS experience. Tec-Masters brings decades of experience in ISS payload integration and certification, ensuring that the electrolysis system will meet stringent spaceflight requirements. The primary objectives of the testing will be to validate that the system can produce oxygen, hydrogen, and electricity reliably in space, crucial for future lunar base operations. This collaboration marks a significant step toward realizing Honda’s vision of sustainable energy systems for space exploration and could reduce the cost and complexity of lunar colonization.

In a Lunar Colony, CRES has the potential to enable a self-sustaining human presence on the Moon, given its ability for in situ resource utilization. Key applications include:

Oxygen Production for Life Support: CRES’s water electrolysis process produces oxygen as a primary output, which can be directly used to sustain colonists, reducing the need for oxygen transport from Earth.

Hydrogen as a Fuel Source: CRES can generate hydrogen as a versatile fuel for various lunar activities, including powering rovers, construction equipment, or spacecraft for cis-lunar operations or return missions to Earth. It can also be used in fuel cells to generate additional electricity, enhancing energy flexibility.

Electricity Generation: The electricity produced by CRES through fuel cells can power the colony’s operations, such as lighting, heating, life support systems, communication equipment, and scientific instruments. This is particularly valuable during the lunar night in lower latitudes, when solar panels can’t generate power due to the absence of sunlight for 14 days.

Closed-Loop Water Recycling: One of CRES’s most significant advantages is its closed-loop design, where water is continuously recycled. Water produced as a byproduct of fuel cell operation is returned to the electrolysis system, minimizing water loss. This is crucial for a lunar colony, where water is a scarce and expensive resource to transport from Earth.

The adoption of CRES in a lunar colony could significantly reduce the need for resupply missions from Earth, lowering costs and logistical complexity. By producing essential life support resources, fuel and electricity on-site, CRES could enable a sustainable lunar economy, supporting long-term habitation which could become a hub for further space exploration, such as missions to Mars.

However, challenges remain, particularly around sourcing water for the system. The quantity and accessibility of lunar water are still being researched, with estimates suggesting ice deposits may be small and dispersed, requiring advanced extraction technologies. Water on the Moon is primarily found in the form of ice deposited in permanently shadowed craters by comets and asteroids over billions of years, especially at the lunar poles, with additional water molecules embedded in lunar soil and rocks due to impingement of the solar wind. Recent research confirms that in addition to water ice in the polar regions, hydration has been found in lower latitude sunlit areas, suggesting a variety of viable sources for CRES. Extraction methods could involve heating lunar regolith to release water or mining ice deposits, though the scale and efficiency of these processes remain areas of active study. The energy required for water extraction and the system’s scalability for a large colony also need further investigation.

Honda’s CRES represents a transformative technology for lunar colonization, offering a pathway to self-sufficiency by leveraging local resources. Its testing on the ISS and eventual integration with lunar water harvesting operations position it as a cornerstone for future space settlement, though ongoing research into water availability and system scalability will be critical for its success.

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Split life cycle approach to settling the solar system

Left: Artist impression of the inside of Kalpana One, a free space settlement providing artificial gravity. Credits: Bryan Veerseeg / Spacehabs.com; Right: Conceptual illustration of a colony on the surface of Mars. Credits: SpaceX.

Until recently, space settlement advocates have typically split into two camps: those who favor building colonies on the surfaces of the Moon or Mars, and those who prefer constructing O’Neill cylinders in free space, spinning to provide artificial gravity outside of planetary gravity wells. Readers of this blog know I lean toward the latter, mainly because colonies on worlds with gravity lower than Earth’s could pose problems for human physiology, particularly reproduction. Truthfully, we won’t know if humans can reproduce in less than 1g until we conduct long-term mammalian reproduction experiments under those conditions. It would be far cheaper and quicker to perform these experiments in Low Earth Orbit (LEO) rather than waiting for sufficient infrastructure to be established on the Moon or Mars for biological research.

Another approach involves not sending humans into space at all, instead entrusting space colonization to human-level artificial general intelligence (HL-AGI) and conscious machines—a non-biological strategy. With recent advancements in AGI and automation, conscious HL-AGI robots may become feasible in the near future (though the exact timeline—whether decades or longer—remains a matter of debate). This prospect might disappoint many space advocates who view migration beyond Earth as the next phase of natural biological evolution hopefully starting within our lifetimes. Deploying sentient machines would effectively remove humanity from the equation altogether.

If you’ve been following space colonization in the press you’ve most likely heard of the book A City on Mars by Kelly and Matt Weinersmith. I have not purchased the book but I’ve read several reviews and heard the authors interviewed by Dr. David Livingston on The Space Show to get an understanding of the Wienersmith’s overall viewpoint, which is at the very least skeptical, and to some space advocates downright anti-settlement. The book is very pessimistic taking the position that the science and engineering of space settlements for large populations of people is too challenging to be realized in the near future.

Peter Hague, an astrophysicist in the UK, wrote an excellent three part review setting the record straight correcting some of the critical facts that the Wienersmith’s get wrong. But in my opinion the best critique by far was written by Dale Skran, Chief Operating Officer & Senior Vice President of the National Space Society (NSS). In a recent post on the NSS blog, he links to a 90 page Critique of “A City on Mars” and Other Writings Opposing Space Settlement in the Space Settlement Journal where he provides a chapter-by-chapter, section-by-section response to the entire book as well as rebuttals to a few other naysayer publications [“Dark Skies” (2021) by Daniel Deudney; “Why We’ll Never Live in Space” (2023) in Scientific American by Sarah Scholes; “The Case against Space” (1997) by Gary Westfahl].

However, Skran credits the Weinersmiths with an innovative idea he hadn’t encountered before, one that addresses the challenge of human reproduction in low gravity. They suggest establishing orbital spin-gravity birthing centers above surface colonies on the Moon or Mars, where children would be born and raised in an artificial gravity environment—essentially a cosmic crèche. Skran builds on this concept, proposing that the life cycle of Moon or Mars colonists could be divided into phases. The first phase would take place in space, aboard rotating settlements with Earth-normal gravity, where couples would conceive, bear children, and raise them to a level of physical maturity—likely early adulthood—determined by prior research. Afterward, some individuals might opt to relocate to the low-gravity surfaces of these worlds. There, surface settlements would focus on various activities, including operations to extract and process resources for building additional settlements.

Skran elaborated on this split life cycle concept and outlined a roadmap for implementing it to settle low-gravity worlds across the solar system during a presentation at the 2024 International Space Development Conference. He granted me permission to share his vision from that presentation and emphasized that the opinions expressed in his talk were his own and did not reflect an official position or statement from the NSS.

Taking a step back, the presentation summarized research that has been performed to date on mammalian physiology in lower gravity, e.g. studies SSP covered previously on mice by JAXA aboard the ISS in microgravity and in the Kibo centrifuge at 1/6g Moon levels. The bottom line is that studies show some level of gravity less then 1g (artificial or otherwise) may be beneficial to a certain degree but microgravity is a horrible show stopper and much more research is needed in lower gravity on the entire reproduction process, from conception through gestation, birth and early organism development to adulthood. The question of reproduction in less then 1g is the elephant in the space station living room. In my presentation at ISDC last year, I took the position that the artificial gravity prescription for reproduction could impact the long term strategy for where to establish biologically self-sustaining space settlements leading to a fork in the road: a choice between O’Neill’s vision of free space rotating settlements vs. lower gravity surface colonies (because outside of the Earth all other solar system worlds where it is practical to establish surface settlements have less then 1g – e.g. the Moon, Mars, Asteroids and the moons of the outer planets – I exclude cloud settlements in Venus’s atmosphere as not realistic). I’ve been swayed by Skran’s proposal and have come to the realization that we don’t need to be faced with a choice between surface settlements or free space artificial gravity habitats – we can and should do both with this split life cycle approach.

How would Skran’s plan for settling the solar system work? He suggests we start small with rotating space settlements in LEO like Kalpana Two, an approach first conceived by Al Globus and popularized in his book coauthored by Tom Marotta The High Frontier: an Easier Way. Locating the habitats in LEO leverages the Earth’s protective magnetic field, shielding the occupants from radiation caused by solar particle events. This significantly reduces their mass and therefore costs because heavy radiation shielding does not need to be launched into orbit. In addition, the smaller size simplifies construction and enables an incremental approach. Kasper Kubica came up with a real estate marketing plan for Kalpana in his Spacelife Direct scenario.

Skran promoted a different design which won the Grand Prize of the NSS O’Neill Space Settlement Contest, Project Nova 2. The novel space station, conceived by a team of high school students at Tudor Vianu National High School of Computer Science, Bucharest Romania, slightly resembles Space Station V from the film 2001: A Space Odyssey. Many other designs are possible.

Project Nova 2 rotating space settlement, one possible design of a rotating space settlement initially built in LEO then moved out to the Moon and beyond. Credit: Tudor Vianu National High School Research Centre Team / NSS O’Neill Space Settlement Contest 2024 Grand Prize Winner

But to get there from here, we have to start even smaller and begin to understand the physics of spin gravity in space. To get things rolling Kasper Kupica has priced out Platform 0, a $16M minimum viable product artificial gravity facility that could be an early starting point for basic research.

Conceptual illustration of Platform 0, a habitable artificial gravity minimum viable product. Credits: Platform 0 – Kasper Kubica / Earth image – Inspiration4

These designs for space habitats will evolve from efforts already underway by private space station companies like Vast, Above, Axiom Space, Blue Origin (with partner Sierra Space) and others. Vast, which has for years had AG space stations on its product roadmap, recently revealed plans to use its orbital space station Haven-1 to be launched in 2026 to study 1/6g Moon level AG in a few years, albeit without crew. And of course let’s not forget last month’s post which featured near term tests proposed by Joe Carroll that could be carried out now using a SpaceX Falcon 9 as an orbital laboratory where researchers could study human adaptation to AG.

Illustration depicting a SpaceX Crew Dragon spacecraft tethered to a Falcon 9 second stage which could be spun up (in direction of down arrow) to test centrifugal force artificial gravity. Credit: Joe Carroll

Back the plan – once the rotating space habitat technology has been proven in LEO, a second and third settlement would be built near the Moon where lunar materials can be utilized to add radiation shielding needed for deep space. The first of these facilities becomes a factory to build more settlements. The second one becomes a cycler, the brilliant idea invented by Buzz Aldrin, initially cycling back and forth in the Earth Moon system providing transportation in the burgeoning cislunar economy just around the corner. The next step would be to fabricate three more copies of the final design. Two would be designated as cyclers between the Earth and Mars. Building at least two makes sense to establish an interplanetary railroad that provides transportation back and forth on a more frequent basis then just building one unit.

Here’s the crown jewel: the third settlement will remain in orbit around Mars as an Earth normal gravity crèche, providing birthing centers and early child development for families settling in the region. Colonists can choose to split their lives between rearing their young in healthy 1g habitats until their offspring are young adults then moving down to live out their lives in settlements on the surface of Mars – or they may choose to live permanently in free space.

This approach enhances the likelihood that settlements on the Moon or Mars will succeed. The presence of an orbiting crèche significantly reduces the risks associated with establishing surface communities by providing an orbital station that can support ground settlements and offer a 1g safe haven to where colonists can retreat if something goes wrong. This alleviates the pressure on initial small crews on the surface, meaning they wouldn’t have to rely solely on themselves to ensure their survival. Finally, an incremental strategy, involving a series of gradual steps with technology readiness proven at each stage through increasingly larger iterations of orbital settlements, offers a greater chance of success.

The final step in this vision for humanity to become a truly spacefaring civilization is to rinse and repeat, i.e. cookie cutter duplication and dispersal of these space stations far and wide to the many worlds beyond Mars with abundant resources and settlement potential. There’s no need to choose between strategies focused solely on surface communities versus spin-gravity colonies in free space. We can pursue both, as they will complement each other, providing families with split life cycle settlement options to have and raise healthy children while tapping the vast resources of the solar system.

Images of resource rich lower gravity worlds beyond Mars with potential for split life cycle settlement (not to scale). Top: the asteroid Ceres. Middle: Jupiter’s Moons, from left to right, Io, Europa, Ganymede, and Callisto. Bottom left: Saturn’s moon Titan. Bottom right: Neptune’s moon Triton. Credits: NASA.
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The benefits of artificial gravity for space settlements

AI generated image of a rotating space station in Earth orbit providing 1g of artificial gravity in the outer ring, with partial gravity in the inner ring and microgravity at the central hub. Credits: Microsoft Designer

SSP has been covering research on artificial gravity (AG) and its impact on space settlement for years. Many of these posts have focused on the Gravity Prescription for human physiology with particular interest in reproduction as humanity will want to ensure that our space settlements are biologically self sustaining (meaning we will want to have children and raise them there). Should we discover that gravity levels on the Moon or Mars are not conducive to couples raising healthy offspring, rotating space settlements with AG may be our only long term option. But there are many other benefits that spin gravity cities can provide for settlers. In a position paper published online last May in Acta Astronautica, gravity researcher Jack J.W.A. van Loon leads a team of European scientists in an exploration of the possibilities and advantages of rotating space stations providing AG. Van Loon founded and manages the Dutch Experiment Support Center (DESC), which provides user support for gravity related research. This study posits a toroidal orbital station large enough and rotating at a sufficient rate to provide 1g of AG in an outer ring, with an intermediate location for partial gravity laboratories and a nonrotating microgravity research facility in a central module.

From an engineering and human factors perspective, pre-flight training would be simplified because practice operations and procedure planning can be performed on the ground in Earth’s normal gravity. Microgravity environments present challenges for physical phenomena like fluid flow, condensation, and heat convection. Provision of a gravity vector eliminates many of these problems simplifying design and use of equipment. This would also reduce development time.

Life support systems utilizing plants to provide breathable air and nutritional sustenance function more naturally and would be less complex in a biosphere with AG. Since plants evolved on Earth to develop gravitropism with roots growing down relative to a gravity vector and shoots sprouting upward, there is no need to develop complex systems to function in microgravity for proper water and nutrient supply as was necessary for NASA’s Passive Nutrient Delivery System aboard the ISS. There would be easier application of hydroponics systems and vertical farming could be leveraged in habitats with AG while harvested fruits and vegetables can be easily rinsed prior to consumption.

With respect to operations, tasks are similar to normal ground based activities so again, less training would be required. Clutter would be reduced and tie downs for tools that tend to float away in microgravity are not necessary. Schedule management would be improved because there would be less time spent on the extra exercise necessary to counteract health problems induced by exposure to microgravity. Activities like showering and sleeping can be challenging in the absence of gravity, so AG would improve the quality of life in regard to these and other routines we take for granted on Earth.

As readers of SSP are aware, the well documented deleterious effects of exposure to microgravity would be mitigated for crews in an AG environment. Such exposure could preserve crew health by preventing losses in bone and muscle mass, cardiovascular deconditioning, weakening of the immune system, vision changes, cognitive degradation and many other spaceflight induced pathologies as documented in the paper’s references. For tourists or visiting researchers, disorientation and days-long adjustment to microgravity due to Space Adaption Syndrome would be prevented.

Safety would be enhanced as well. For instance, combustion processes and flames behave very differently in microgravity making fire suppression less well understood when compared to normal gravity, necessitating development of new safety procedures. Free floating liquids and tools tend to move around unrestricted causing hazards that could potentially short out electrical equipment. Microorganisms and mold could present a health hazard as humidity control is problematic without a gravity vector. Surgery and medical procedures have not been developed for weightless conditions, requiring specially designed equipment and processes. Liquids drawn from vials containing drugs behave differently in microgravity because of surface tension effects. As mentioned above, training for all activities and equipment designed for use in Earth-normal gravity can be performed ahead of time on the ground. Testing of flight hardware would be simplified as it would not need to be redesigned for use in microgravity. Finally, decades of health studies on astronauts in space under microgravity conditions have found that pathological microorganisms are less responsive to antibiotics while at the same time, become more virulent. AG could make these microbes respond as expected on Earth.

The space station proposed in this paper would include an inner ring housing hypogravity facilities where AG equivalent to levels of the Moon and Mars could be provided for investigators to study and tourists to experience. Mammalian reproduction could be studied in ethical clinical experiments to determine if conception, gestation, birth and maturation to adulthood is possible in lower gravity over multiple generations, starting with rodents and progressing to higher primates. The central module would provide a microgravity science center for zero-g basic research or manufacturing where scientists could perform experiments then return to the outer ring’s healthy 1g conditions.

The author’s budgetary analysis found that the cost of such a facility would be about 5% higher than a microgravity habitat due to increased mass for propulsion and supplementary structures, but the benefits outlined above would be an acceptable trade off enabling a better quality of life for tourists and permanent inhabitants. This concept could be the first step in validating health studies and living conditions in artificial gravity informing the design of larger free space settlements.

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Progress on mammalian reproduction in microgravity

AI generated image of an expectant mother with her developing fetus in Earth orbit after mammalian reproduction has been validated via higher animal models through all stages of pregnancy for a safe level of gravity. An appropriate level of radiation shielding would also be required and is not shown in this illustration. Credits:DALL∙E 3

We are one step closer to determining the gravity prescription for human reproduction in space. Okay, so we still don’t have the green light for having children at destinations in space with less than normal Earth gravity or higher radiation environments….yet. But a team of Japanese scientists report positive results after running an experiment aboard the International Space Station in 2019 that examined mouse embryos cultured in both microgravity and artificial gravity in space, then compared them to controls on Earth after a few days of development. The researchers published their results in a paper in iScience.

The researchers developed equipment and a protocol for freezing two-cell embryos after fertilization on the ground and launching them to the ISS where they were thawed then split into two groups, one allocated to growth in microgravity, the other treated with spin gravity to artificially simulate 1g. A control group remained on Earth. The procedure was designed to be executed by untrained astronauts. Cultured growth continued for 4 days after which the samples were preserved and refridgerated until they could be returned to Earth for analysis.

The samples were also monitored for radiation with a dosimeter and as expected aboard the ISS, were exposed to radiation levels higher then developing fetuses experience on the ground but far lower than those known to exist in deep space outside the Earth’s atmosphere and protective magnetic field. Still, this can be a “worst case” data point for radiation exposure to developing embryos as it is unlikely that pregnancy would be ethically sanctioned at higher levels.

Upon thawing by astronauts, the embryos were cultured through initial mitosis to eventual cell differentiation and blastocyst formation. A blastocyst is the multicellular structure of early embryonic development consisting of an an outer layer of cells called the trophectoderm surrounding a fluid-filled cavity in which an inner cell mass (ICM) called the embryoblast eventually develops into the embryo.

The study was concerned with how gravity may influence cell differentiation, the placement of the ICM within the blastocyst and if radiation effects gene expression in the these cells which will later develop into the fetus. Gene expression within the trophectoderm is also critical for proper development of the placenta.

The results were very promising as the data showed that there were no significant effects on early cell differentiation during embryo development and that proper gene expression manifested in microgravity when compared to 1g artificial and normal Earth gravity.

A human blastocyst with the inner cell mass at upper right. Credits: Wikipedia

A highlight of the paper implied that the results indicate that “Mammals can thrive in space.” It is too early to make such a bold statement with only this one study. It should be noted that this experiment only focuses on one early stage of embryo development. Conception in microgravity is not addressed and as pointed out by Alex Layendecker of the Astrosexological Research Institute, may have a whole other set of problems that raise ethical concerns as may the effects of lower gravity on later stages of gestation, in actual live birth and in early child development.

No matter how positive these recent results appear to be for early embryo development, as was determined by a landmark experiment on pregnant mice during the Shuttle era, we already have a data point on mammalian fetal development in later stages of gestation in microgravity: serious brain developmental issues were discovered in mice offspring born after exposure to these conditions. So mammalian reproduction in microgravity may start out relatively normally (assuming conception is successful) but appears to have problems in later stages, at least according to the limited data we have so far. On the bright side, the recent study found that 1g artificial gravity had no significant effects on embryo development.

Clearly more data is needed to determine which level of gravity will be sufficient for all stages of mammalian reproduction in space. Fortunately, SpaceBorn United is working on this very problem. They have plans for research into all stages of human reproduction in space to enable independent human settlements off Earth. SpaceBorn CEO Egbert Edelbroek in a recent appearance on The Space Show described upcoming missions later this decade that will study mammalian conception and embryo development using the company’s assisted reproductive technology in space (ARTIS). They have developed a space-embryo-incubator that will contain male and female mouse gametes, which upon launch into orbit, will initiate conception to create embryos for development in variable gravity levels. After 5-6 days the embryos would be cryogenically frozen for return to Earth where they would be inspected and if acceptable, placed in a natural womb for the rest of pregnancy and subsequent birth. If successful with mice the the company plans experiments with human stem cell embryos and eventually human gametes.

The gravity prescription for human reproduction in less than normal Earth gravity is still not known. But at least researchers are starting to gather data on this critical factor for long term biologically sustainable space settlement.

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Crops in space: providing sustenance and life support for settlers

Roadmap for research and infrastructure development for growing crops in space for human sustenance and life support, from the ISS to Mars. Credits: Grace L. Douglas, Raymond M. Wheeler and Ralph F. Fritsche

Space settlement advocates know that we will have to take our biosphere with us to space to produce food, provide breathable air and recycle wastes. Completely closing the system, i.e. recycling everything is a huge technological challenge, especially on a small scale like what is planned for settlements in free space or on the surfaces of the Moon or Mars. Fortunately, there are plenty of raw materials in the solar system for in situ resource utilization so we can live off the land, so to speak, until our bioregenerative life support system efficiencies improve.

Early research into crop production in space has been performed on the ISS. But the road ahead for space agriculture in the context of life support systems needs careful planning to pave the way toward biologically self-sustaining space settlements. A team of scientists at NASA is working on a roadmap toward sustainability with a step-by-step approach to bioregenerative life support systems (BLSS) that will provide food and oxygen for astronauts during the space agency’s mission plans in the decades ahead. In a paper in the journal Sustainability they identify the current state of the art, resource limitations and where gaps remain in the technology while drawing parallels between ecosystems in space and on Earth, with benefits for both.

Simulation and modeling of BLSS concepts is important to predict their behavior and help inform actual hardware designs. A team at the University of Arizona performed a study recently analyzing the inputs and outputs of such a system to improve efficiencies and apply it to food production on Earth in areas challenged by resource limitations and food insecurity. Sustainable ecosystems for supporting humans on and off Earth have similar goals: minimizing growing space, water usage, energy needs and waste production while simultaneously maximizing crop yields. The team presented their findings in a paper presented at the 50th International Conference on Environmental Systems held last July. In the study, a model of an ecosystem was created consisting of various combinations of plants, mushrooms, insects, and fish to support a population of 8 people for 183 days with an analysis of total growing area, water requirements, energy consumption and total wastes produced. The study concluded that “In terms of resource consumption, the strategy of growing plants, mushrooms, and insects is the most resource-efficient approach.”

At the same conference, an update was provided on a Scalable, Interactive Model of an Off-World Community (SIMOC). SIMOC was described in a previous post on the Space Analog for the Moon and Mars (SAM) located at Biosphere 2 in Arizona. SIMOC is a platform for education meeting standards for student science curriculum. Pupils or citizen scientists can customize human habitats on Mars by selection of mission duration, crew size, food provisions as well as choosing types of plants, levels of energy production, etc.. Users gain an understanding of the complexity of a BLSS and the tradeoffs between mechanical and biological variables of life support for long duration space missions. There is much to be learned on the limitations and stability of closed biospheres, as discussed last year.

Image of Biosphere 2, a research facility to support the development of computer models that simulate the biological, physical and chemical processes to predict ecosystem stability. Credits: Biosphere 2 / University of Arizona

Across the Pond, our European friends at LIQUIFER Systems Group are working on greenhouses for the Moon and Mars derived from the EDEN ISS simulation facility in Antarctica.

A BLSS based on plant biology could be augmented with dark ecosystems, the food chain based on bacteria that are chemotrophic, i.e. deriving their energy from chemical reactions rather then photosynthesis, which could significantly reduce the inputs of energy and water.

A concept for a lunar farm called Lunar Agriculture, Farming for the Future was published in 2020 by an international team of 27 students participating in the Southern Hemisphere Space Studies Program at the International Space University.

Layout of a potential subsurface lunar farm. Credits: International Space University and University of South Australia

As a treat to cap off this post, a retired software engineer and farmer named Marshall Martin living in Oklahoma provided his perspective on crops in space on The Space Show recently. A frequent caller to the program, this was his first appearance as a guest where, like the NASA team mentioned earlier, he recommends a phased approach to space farming starting with small orbital facilities, testing inputs and outputs as we go, to ensure the economics pay off at each stage of our migration off Earth. He even envisions chickens and goats as sources of protein and milk, although the weight limitations for inclusion of these animals in space-based ecosystems may not be possible for quite some time. Its unlikely that cows will ever make it to space but cultured meat production is a real possibility for the carnivores among us which is being studied by ESA.

Cattle in the cargo bay of the Firefly-class transport spaceship Serenity. Cows probably won’t make it to space because of weight, volume and resource limitations but cultured meat is a real possibility. Image from the television series Firefly. Credits: Josh Whedon/ Mutant Enemy, Inc. in associations with Twentieth Century Fox Television

Finally, for those thinking long term of eventual settlement of the galaxy, there are even some people modeling life support systems for interstellar arks.

Image of the interior of a worldship habitat for interstellar travel. Credits: Michel Lamontagne / Principium, Issue 32, February 2021

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Update on the Photonic Laser Thruster and the interplanetary Photonic Railway

Diagram depicting the layout of the Photonic Laser Thruster (PLT). Credits: Young K. Bae, Ph.D.

SSP reported last year on the promise of an exciting new Photonic Laser Thruster (PLT) that could significantly reduce travel times between the planets and enable a Phonic Railway opening up the solar system to rapid exploration and eventual settlement. The inventor of the PTL, Dr. Young K. Bae has just published a paper in the Journal of Propulsion and Power (behind a paywall) that refines the mathematical underpinnings of the PLT physics and illuminates some exciting new results. Dr. Bae shared an advance copy of the paper with SSP and we exchanged emails in an effort to boil down the conclusions and clarify the roadmap for commercialization.

Illustration of a Photonic Railway using PLT infrastructure for in-space propulsion established at (from right to left, not to scale) Earth, Mars, Jupiter, Pluto and beyond. Credits: Young K. Bae.

In the new paper, Dr. Bae refines his rigorous analysis of the physics behind the PLT confirming previous projections and discovering some exciting new findings.

As outlined in the previous SSP post linked above, the PLT utilizes a “recycled” laser beam that is reflected between mirrors located at the power source and on the target spacecraft. Some critical researchers have argued that upon each reflection of the beam off the moving target mirror, there is a Doppler shift causing the photons in the laser light to quickly lose energy which could prevent the PLT from achieving high spacecraft velocities. The new paper conclusively proves such arguments false and confirming the basic physics of the PLT.

There were two unexpected findings revealed by the paper. First, the maximum spacecraft velocity achievable with the PLT is 2000 km/sec which is greater than 10 times the original estimate. Second, the efficiency of converting the laser energy to the spacecraft kinetic energy was found to approach 50% at velocities greater than 100 km/s. This is surprisingly higher than originally thought and is on a par with conventional thrusters – but the PLT does not require propellent. These results show conclusively that once the system is validated in space, the PLT has the potential to be the next generation propulsion system.

I asked Dr. Bae if anything has fundamentally changed recently in photonic technology that will bring the PLT closer to realization. He said that the interplanetary PLT can tolerate high cavity laser energy loss factors in the range of 0.1-0.01 % that will permit the use of emerging high power laser mirrors with metamaterials, which are much more resistant to laser induced damage and are readily scalable in fabricating very large PLT mirrors.

With respect to conventional thrusters, he said the PLT can be potentially competitive even at low velocities on the order of 10 km/s, especially for small payloads. This is because system does not use propellant which is very expensive in space and because the PLT launch frequency can be orders of magnitude higher than that of conventional thrusters. Dr. Bae is currently investigating this aspect of the system in terms of space economics in depth.

The paper acknowledges that one of the most critical challenges in scaling-up the PLT would be manufacturing the large-scale high-reflectance mirrors with diameters of 10–1000m, which will likely require large-scale in-space manufacturing. Fortunately, these technologies are currently being studied through DARPA’s NOM4D program which SSP covered previously and Dr. Bae agreed that they could be leveraged for the Photonic Railway.

Artist’s concept of projects, including large high-reflectance mirrors, which could benefit from DARPA’s (NOM4D) plan for robust manufacturing in space. Credits: DARPA

I asked Dr. Bae about his timeline and TRL for a space based demo of his Sheppard Satellite with PLT-C and PLT-P propellantless in-space propulsion and orbit changing technology. He responded that such a mission could be launched in five years assuming there were no issues with treaties on space-based high power lasers. There is The Treaty on the Prevention of the Placement of Weapons in Outer Space but I pointed out that the U.S. has not signed on to this treaty. Article IV of the Outer Space Treaty states that “…any objects carrying nuclear weapons or any other kinds of weapons of mass destruction…” can not be placed in orbit around the Earth or in outer space. Dr. Bae said “We can argue that the [Outer Space] treaty regulation does not apply to PLT, because its energy is confined within the optical cavity so that it cannot destroy any objects.  Or we can design the PLT such that its transformation into a laser weapon can be prevented.”

He then went on to say: “For space demonstration of PLT spacecraft manipulation including stationkeeping, I think using the International Space Station platform would be one of the best ways … I roughly estimate it would take $6M total for 3 years for the demonstration using the ISS power and cubesats. The Tipping Point [Announcement for Partnership Proposals] would be a good [funding mechanism] …to do this.”

Once the technology of the Photonic Railway matures and is validated in the solar system Dr. Bae envisions its use applied to interstellar missions to explore exoplanets in the next century as described in a 2012 paper in Physics Procedia.

Conceptual illustration of the Photonic Railway applied to a roundtrip interstellar voyage to explore exoplanets around Epsilon Eridani. This application requires four PLTs: two for acceleration and two for deceleration. Credits: Young K. Bae

Be sure to listen live and call in to ask Dr. Bae your questions about the PLT in person when he returns to The Space Show on March 29th.

Update May 9, 2025: Dr. Bae has further refined his concept in a new book, Photonic Laser Propulsion. He returned to The Space Show to talk about it with Dr. David Livingston.

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Moon-Mars dumbbell variable gravity research facility in LEO

Conceptual illustration depicting the deployment sequence of a LEO Moon-Mars dumbbell partial gravity facility serviced by SpaceX’s Starship. Left: Starship payloads being moored by a robot arm. Center: 1.6 m ID inflatable airbeams (yellow) play out from spin access and mate with dumbbell end modules. Rectangular solar arrays deploy by hanging at either end as spin is initiated via thrusters at Mars module. Right: Full deployment with Starship and Dragon docked at spin axis hub. Credits: Joe Carroll via The Space Review

There may be no single human factor more important to understand on the road to long term space settlement than determination of the gravity prescription (GRx) for healthy living in less than Earth normal gravity. What do we mean by the GRx? With over 60 years of human space flight experience we still only have two data points for stays longer than a few days to study the effects of gravity on human physiology: microgravity aboard the ISS and data here on the ground. Based on medical research to date, we know that significant problems arise in human health after months of exposure to microgravity. To name a few, osteoporosis, immune system degradation, diminished muscle mass, vision problems due to changes in interocular pressure and cognitive impairment resulting memory loss and lack concentration. Some of these problems can be mitigated with a few hours of daily exercise. But recovery upon return to normal gravity takes considerable time and we don’t know if some of these problems will become irreversible after longer term stays. We have virtually no data on human health at gravity levels of the Moon and Mars, as shown in this graph by Joe Carrol:

Graph of the correlation between human health vs gravity showing the two data points where we have useful data. Whether the relationship is a linear function or something more complex is an unknown of great importance for space settlement. Credits: Joe Carrol presentation at Starship Congress 2019 and Jon Goff post on Selenium Boondocks Nov 29, 2005

The more important question for permanent space settlements is can humans have babies in lower gravity? If we go by the National Space Societies’ definition, an outpost will never really become a permanent space settlement until it is “biologically self-sustaining”. We evolved over millions of years at the bottom Earth’s gravity well. How will amniotic fluid, changes in cell growth, fetal development and human embryos be affected during gestation under lower gravity conditions on the Moon or Mars? There are already indications that problems will arise during mammalian gestation, at least in microgravity as experienced aboard the ISS.

To answer these questions, Joe Carroll suggests the establishment of a crewed artificial gravity research facility in LEO which he described last month in an article in The Space Review. He proposes a Moon-Mars dumbbell with nodes spinning at different rates to simulate gravity on both the Moon and Mars, which covers most of the planetary bodies in the solar system where settlements would be established if not in free space. The facility could be launched and tended by SpaceX’s Starship once the spacecraft is flight worthy in the next few years in parallel with Elon Musk’s plans to establish an outpost on Mars. Musk may even want to fund this facility to inform his long term plans for communities on Mars. If his goal is for the humanity to become a multiplanetary species, surely will want to know if his settlers can have children.

Carroll’s design connects the Moon and Mars modules with radial structures called “airbeams” which will allow crew to access the variable gravity nodes in a shirtsleeve environment. The inflatable members are composed of polymer fiber fabric which can be easily folded for storage in the Starship payload bay. Crews would be initially launched aboard Dragon until the Starship is human rated.

“Eventually, rotating free-space settlements will get massive enough to use other shapes, but dumbbells plus airbeams seem like the key to useful early ones.”

The paper addresses details on key operating concepts, docking procedures, emergency protocols, and the implications for long term settlement in the solar system.

There may even be a market for orbital tourism to experience lower gravity that could make funding for the facility attractive to space venture capitalists, especially if it is located in an equatorial orbit shielded from ionizing radiation by the Earth’s magnetic fields. As the technology matures, older tourists may even want to retire in orbital communities that offer the advantage of lower gravity as their bodies become frail in their golden years.

Humankind’s expansion out into the solar system depends on where we can survive and thrive in a healthy environment. If ethical clinical studies on lower mammals in a Moon/Mars dumbbell clears the way for a healthy life in lunar gravity then we can expand out to the six largest moons including our own plus Mars. If the data shows we need at least Mars gravity, then the Red Planet or even Mercury could be potential sites for permanent settlement. But if nothing below Earth normal gravity is tolerable, especially for mammalian gestation, it may be necessary to build ever larger rotating O’Neillian free space settlements to expand civilization across the solar system. There are vast resources and virtually unlimited energy if we need to do that. But it will take considerable time and careful planning to establish the vast infrastructure needed to build these settlements. If human physiology is constrained by Earth’s gravity then space settlers will want to know this information soon so that the planning process can be integrated into space development activities about to unfold on the Moon and beyond. If Musk finds out that Mars inhabitants cannot have children and wants to establish permanent communities beyond Earth, would he change course and switch to O’Neillian free space settlements?

“If we do need sustained gravity at levels higher than that of Mars, it seems easier to develop sustainable rotating settlements than to terraform any near-1g planet.”

Listen to Joe Carroll answer my questions about his Moon/Mars dumbbell facility from earlier this month on this archived episode of The Space Show.

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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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ESA’s Biorock experiment demonstrates microbe extraction of rare Earth elements from simulated regolith aboard ISS

ESA astronaut Luca Parmitano loads microbes into the Kubik centrifuge facility on the International Space Station. Credits: ESA

A research team at the University of Edinburgh in the UK has just published an analysis of data from an experiment on the International Space Station that could lead to “biomining” on Mars or an asteroid. Published in Nature Communications on November 10, Cockell, C.S., Santomartino, R., Finster, K. et al.* present experimental results demonstrating microbiological leaching of rare Earth elements from basalt rock, an analogue for much of the regolith material on the Moon and Mars. Called BioRock, the ESA sponsored experiment examined three species of microorganisms under variable gravity conditions in the Kubik centrifuge facility located in Europe’s Columbus module on the ISS.

This technology is a significant breakthrough for in situ resource utilization. By “living off the land” on the Moon, Mars or an asteroid, space settlers could have an available source of valuable materials used in electronic devices and many other high-technology applications. These rare Earth elements and the traditional heavy mining equipment needed to extract them would not have to be launched from Earth, significantly reducing transportation and processing costs. Positive results were found under Earth gravity, Mars gravity and microgravity conditions. The authors conclude that the experiment “…shows the efficacy of microbe–mineral interactions for advancing the establishment of a self-sustaining permanent human presence beyond the Earth and the technical means to do that.”

* BioRock study Authors: Charles S. Cockell, Rosa Santomartino, Kai Finster, Annemiek C. Waajen, Lorna J. Eades, Ralf Moeller, Petra Rettberg, Felix M. Fuchs, Rob Van Houdt, Natalie Leys, Ilse Coninx, Jason Hatton, Luca Parmitano, Jutta Krause, Andrea Koehler, Nicol Caplin, Lobke Zuijderduijn, Alessandro Mariani, Stefano S. Pellari, Fabrizio Carubia, Giacomo Luciani, Michele Balsamo, Valfredo Zolesi, Natasha Nicholson, Claire-Marie Loudon, Jeannine Doswald-Winkler, Magdalena Herová, Bernd Rattenbacher, Jennifer Wadsworth, R. Craig Everroad & René Demets