Progress on automated deployment of lunar habitats

Automated deployment sequence of a prototype lunar habitat floor plate structure using a gas inflation system. Credits: Luke Brennan

It is obvious that establishing settlements on the Moon with be difficult. It’s a harsh environment presenting many risks to the health of humans who may wish to live there including radiation, bombardment by micrometeorites, lack of breathable air, and a host of other hazards which will demand rigorous engineering solutions to design safe and livable structures. But Haym Benaroya, professor of mechanical and aerospace engineering at Rutgers University is up for the challenge. In fact, he literally wrote the book on engineering approaches to building lunar habitats. He and his students have been developing novel methods for automated deployment of structures to house future lunar explorers. These type of engineering solutions would allow deployment of large habitable structures prior to the arrival of occupants, thereby minimizing radiation exposure. SSP has had the privilege of covering one such novel approach that combines a foldable rigid framework with an inflatable dome called the Hybrid Lunar Inflatable Structure, the subject of the master’s thesis of one of the professor’s students, Rohith Dronadula.

In a recent paper in Acta Astronautica, a group of Benaroya’s students further refined this approach. Luke Brennan, coauthor on the article, provided the following remarks on progress of the design effort:

“The hybrid lunar inflatable structure (HLIS) underwent three years of development by student teams at Rutgers University to go from an initial concept laid out by Dronadula and Benaroya [2021] to a functioning proof of concept. The design combines safety elements found in rigid structures with the large habitable volumes offered by inflatable designs through an inflatable membrane attached to the rigid center column. The baseplates are folded during transportation to better fit within rocket payloads and can be deployed autonomously once on the lunar surface. When unfolded, the structure expands 2.25x in diameter, representing a 5x increase in floor area.

“Manufacturing constraints set the foundation for the design process. Ensuring an autonomous deployment is key, as the threat of radiation posed to astronauts on the lunar surface restricts them from being able to reasonably assist in constructing the structure. A novel deployment mechanism was introduced, which used a dynamic O-ring to displace and initiate baseplate deployment and membrane inflation. Compressed air will need to be included in habitats regardless of the deployment strategy, so the deployment utilized this by triggering deployment when the gas is released. The internal pressure acts on the component containing the dynamic O-ring, lifting it. The displaced component is attached to the top cap, which contains the baseplates when stowed, and releases the baseplates when lifted. The full displacement of the O-ring exposes an air passageway through the center column, allowing gas to escape into the membrane.

“The first image [above] demonstrates this working concept, where generic SodaStream bottles were used inside the center column with a solenoid to toggle the CO2 release. Unfortunately, as CO2 gets released, the temperature drop can lead to solid CO2 (dry ice) accumulating at the pressure reducer. This ultimately starved the flow, preventing a full bottle from being emptied, which was necessary for proper membrane inflation. This can be resolved using a heated pressure reducer but introduces significantly more complexity, so this was neglected. However, the working proof of concept provides a great platform for future research to build on.”

This work exemplified the key takeaway Benaroya makes in his book Building Habitats on the Moon: “…we need to understand how the reliability of engineered systems can be improved in the unforgiving space and lunar environment and, synergistically with reliability, how to ensure that humans and other living systems can survive and thrive physically and psychologically in that environment.”

Progress on inflatable lunar habitats

Conceptual illustration of a Moon base composed of inflatable habitats near one of the lunar poles. Credits: ESA / Pneumocell

The European Space Agency (ESA) recently published a report on a design study of an inflatable lunar habitat. The work was done by Austrian based Pneumocell in response to an ESA Open Space Innovation Platform campaign. The concept utilizes ultralight prefabricated structures that would be delivered to the desired location, inflated and then covered with regolith for radiation protection and thermal insulation. The main components of the habitat are toroidal greenhouses that are fed natural sunlight via a rotating mirror system that follow the sun. Since the dwellings are located at one of the lunar poles, horizontal illumination is available for most of the lunar night. Power is provided by photovoltaic arrays attached to the mirror assemblies. During short periods of darkness power is provided by batteries or fuel cells.

Cutaway view of the inflatable lunar habitat. Credits: ESA / Pneumocell

The detailed system study worked out engineering details of the most challenging elements including life support, power sources, temperature control, radiation protection and more. The greenhouses would provide sustenance and an environmentally controlled life support system for two inhabitants recycling everything. The authors claim that “…it appears possible to create in the long term a closed system…” This remains to be validated.

Inflatable space habitats have many advantages over rigid modules including lower weight, packaging efficiency, modularity and psychological benefit to the inhabitants because after deployment, the interior living space is much larger for a given mass. Several organizations and individuals have already begun to investigate inflatable habitats for lunar applications. The Pneumocell study mentions ESA’s Moon Village SOM-Architects concept which is a hybrid rigid and partly inflatable structure. Also referenced is the Foster’s and Partners Lunar Outpost design which envisions a 3D printed dome shaped shell formed over an inflatable enclosure.

Foster and Partners Lunar Outpost constructed from a hybrid of 3D printed modules and an inflatable structure. Credits: Foster and Partners

SSP previously covered another hybrid lunar inflatable structure designed by Rohith Dronadula. This design combines a collapsible rigid framework with an inflatable dome, can be autonomously launched from Earth and deployed through telepresence.

Illustration of a hybrid lunar inflatable structure. Credits: Rohith Dronadula

The Pneumocell report concludes: “A logical continuation of this study would be to build a prototype on Earth, which can be used to investigate various details of the suggested components … ” Such an approach would be relatively inexpensive and could inform the future design of flight hardware.

Speaking of ground based prototypes, The Space Development Network has been exploring inflatable structures for habitats on the Moon for some time. Doug Plata, president of the nonprofit organization working to advance space development hopes to display an inflatable version of his InstaBase concept at BocaChica, Texas when SpaceX attempts its first orbital launch of Starship, hopefully within the a year or so. When comparing his design to Pneumocell’s, Plata says in an email to SSP, “One difference is that we have the modules directly attached to each other and so avoid the mass of those connecting corridors.”

Conceptual illustration of InstaBase – a fully inflatable lunar base capable of supporting an initial crew of eight. Credits: The Space Development Network

In reference to the greenhouse designs, Plata continues: “As for the GreenHabs, they have a pretty interesting design to take advantage of direct sunlight. We address the shielding conceptually by fully covering the GreenHabs and then use PV solar drapes and transport the electricity into the GreenHabs via wires. By converting sunlight to electricity to LEDs, more surface area of plants can be grown than the surface area of the solar panels powering them. This is due to the full spectrum of the sun being converted to only those frequencies that plants use.”

It is great to see such creativity and variety of designs for abodes on the Moon. When reliable transportation systems such as Starship blaze the trail, we will be ready with easily deployable, safe and voluminous habitats for lunar settlements.

Artist rendering of the interior of an inflatable toroidal greenhouse in a lunar habitat. Credits: Pneumocell

Redwire wins first place in NASA’s Breaking the Ice Lunar Challenge

Image of Lunar Transporter (L-Tran) with Lunar Regolith Excavator (L-Rex) stored on board as they roll down a ramp from a lunar lander. Credits: screen capture from Redwire Space animation. All images below are so credited.

NASA has just announced the winners of the Breaking the Ice Lunar Challenge, an incentive program for companies to investigate new approaches to ISRU for excavating icy regolith from the Moon’s polar regions. The agency will be awarding half a million dollars in cash prizes and Redwire Space headquartered in Jacksonville, Florida won first prize scoring $125,000 for its elegantly designed two rover lunar excavation system. The criteria used by NASA to select the winners was based on maximum water delivery, minimum energy use, and lowest-mass equipment.

Upon delivery by a lunar lander near a shadowed crater in the Moon’s south polar region, a multipurpose Lunar Transporter (L-Tran) carrying a Lunar Regolith Excavator (L-Rex) rolls down a ramp to begin operations on the surface. The rover transports the excavator to the target area where icy regolith has been discovered.

Image of L-Rex driving off of L-Tran

The L-Rex then drives off the L-Tran to start collecting regolith in rotating cylindrical drums on the front and back of the vehicle.

L-Rex collecting lunar regolith in fore and aft collection drums
L-Rex loading regolith into L-Tran for transport back to processing station

When the drums are full, L-Rex returns to the rover and deposits its load in L-Tran’s storage bed. L-Rex repeats this process over many trips until L-Tran is loaded to capacity at which point the rover returns to a processing facility to separate the water from the regolith.

L-Tran dumping a load of regolith into a hopper at a processing facility
After regolith beneficiation the separated frozen water ice is loaded into L-Tran for transport to secondary processing plant

Upon separation into purified frozen ice, L-Tran is once again loaded up with the product for transport to a station for storage or perhaps, further processing. No further details were provided but the final process is presumed to be electrolysis of the water into useful end products such as H2 and O2 for rocket fuel or life support uses, plus simply storage as drinking water for human habitation.

L-Tran loading water ice into hopper for final processing into end products or simply storage

The second place prize of $75,000 was awarded to the Colorado School of Mines in Golden, Colorado for its Lunar Ice Digging System (LIDs). The LIDS proposal has three rovers – an excavator, regolith hauler, and water hauler each of which would be teleoperated from a nearby lunar surface habitat.

Austere Engineering of Littleton, Colorado won the $50,000 third place prize for its Grading and Rotating for Water Located in Excavated Regolith (GROWLER) system. The system weighs slightly more then a school bus tipping the scales at an estimated mass of 12 metric tons.

A second phase of the challenge, if approved, could move the proposals into hardware development and a future demonstration mission toward eventual support of lunar habitats and a cislunar economy.

Checkout Redwire’s animation of their lunar excavation system:

Animation from Redwire Space’s Breaking the Ice Lunar Challenge proposal. Credits: Redwire Space

Design solutions for safe lunar habitats

Artist’s impression of an inflatable habitat on the Moon. Credits / NASA, Gary Kitmacher

Haym Benroya, Distinguished Professor of Mechanical and Aerospace Engineering at Rutgers University and author of Turning Dust to Gold, Building a Future on the Moon and Mars gave a presentation recently at a workshop of the Engineering and Physical Sciences Research Council. EPSRC is the main funding body for engineering and physical sciences research in the UK. The event kicked of a project sponsored by the EPSRC called Designing for the Future: Optimizing the structural form of regolith-based monolithic vaults in low-gravity conditions. Benroya shared his presentation with me in which he discusses the design challenges and solutions to optimize a reliable and safe lunar habitat.

The design of space settlements on the Moon will have an array of engineering challenges including protection from radiation, meteoroids, temperature extremes and Moonquakes. In addition, human factors such as psychological and physiological aspects associated with isolation and the lower gravity conditions need to be taken into consideration. This presentation summarizes all the key design constraints, especially those surrounding the thermal and seismic conditions, laying the engineering groundwork for safe dwellings that will be erected when we return to the Moon, hopefully this time to stay and thrive.

For the technically inclined who want more information on lunar settlement design methodology be sure and check out Benroya’s excellent book Building Habitats on the Moon: Engineering Approaches to Lunar Settlements.

And don’t miss our appearance along with Dr. David Livingston of The Space Show and Moonwards‘ Kim Holder at the Icarus Interstellar 2017 Starship Congress.

Resilient ExtraTerrestrial Habitats

Shirley Dyke, Professor of Mechanical Engineering and Civil Engineering at Purdue University is the head of the school’s RETH (Resilient ExtraTerrestrial Habitats) Institute. Her work seeks an understanding of what characteristics make habitats safe through “cyber physical testing”, a discipline that combines computer models with physical testing to validate results. A habitat’s resilience level is paramount to this endeavor, which results in intelligently designed structures that mitigate risks of numerous hazards to humans anticipated in the lunar environment. Her team models the effects of meteoroid impacts, moon quakes, problems with lunar regolith (which is highly abrasive) and others that may impact the performance of outposts on the Moon.

Credits: Purdue University photo illustration/Mark Simons

Project “Lunark Habitat”

A danish design company called SAGA Space Architects has developed an origami-like folding structure for space habitation. Designed for two astronauts, the exterior is composed of an aluminum frame layered with solar cells”, while the interior has living quarters with desks and shelves. The designers, Sebastian Aristotelis and Karl-Johan Sorensen will test the facility this fall in arctic conditions for three months in Greenland.

Design of the LUNARK Mark 1 Habitat, an origami-inspired expandable moon shelter.
Credit: SAGA Space Architects
LUNARK
Credit: SAGA Space Architects

Breakthrough mission architecture for mining lunar polar ice

Joel Sercel of Trans Astronautica Corporation was recently awarded a Phase II NIAC grant for a Lunar Polar Mining Outpost (LPMO) that promises to greatly reduce the cost of commercializing propellant production on the Moon. The system utilizes two patented innovative concepts for generating power and processing regolith. The first invention is a several meters tall solar reflector tower called a Sun Flower™ to gather sunlight at the permanently illuminated areas near the poles and reflect it down to megawatt level solar arrays near the outpost. The second concept called Radiant Gas Dynamic (RGD) mining combines microwave and infrared radiation to sublimate ice out from the regolith for storage in cryotraps on electric powered rovers. The outpost elements are designed to be delivered to the lunar surface using Blue Origin’s New Glenn rocket and Blue Moon lander.

Sercel states that “…LGMO promises to vastly reduce the cost of establishing and maintaining a sizable lunar polar outpost that can serve first as a field station for NASA astronauts exploring the Moon, and then as the beachhead for American lunar industrialization, starting with fulfilling commercial plans for a lunar hotel for tourists”

Diagram of Lunar Polar Propellant Mining Outpost (LPMO) concept
Credits: Joel Sercel