3D printing will help space pioneers make homes, tools and other stuff they need to colonize the Moon and Mars

Sven Bilén, Penn State

Throughout history, when pioneers set out across uncharted territory to settle in distant lands, they carried with them only the essentials: tools, seeds and clothing. Anything else would have to come from their new environment.

So they built shelter from local timber, rocks and sod; foraged for food and cultivated the soil beneath their feet; and fabricated tools from whatever they could scrounge up. It was difficult, but ultimately the successful ones made everything they needed to survive.

Something similar will take place when humanity leaves Earth for destinations such as the Moon and Mars – although astronauts will face even greater challenges than, for example, the Vikings did when they reached Greenland and Newfoundland. Not only will the astronauts have limited supplies and the need to live off the land; they won’t even be able to breathe the air.

Instead of axes and plows, however, today’s space pioneers will bring 3D printers. As an engineer and professor who is developing technologies to extend the human presence beyond Earth, I focus my work and research on these remarkable machines.

3D printers will make the tools, structures and habitats space pioneers need to survive in a hostile alien environment. They will enable long-term human presence on the Moon and Mars.

From hammers to habitats

On Earth, 3D printing can fabricate, layer by layer, thousands of things, from replacement hips to hammers to homes. These devices take raw materials, such as plastic, concrete or metal, and deposit it on a computerized programmed path to build a part. It’s often called “additive manufacturing,” because you keep adding material to make the part, rather than removing material, as is done in conventional machining.

Already, 3D printing in space is underway. On the International Space Station, astronauts use 3D printers to make tools and spare parts, such as ratchet wrenches, clamps and brackets. Depending on the part, printing time can take from around 30 minutes to several hours.

For now, the print materials are mostly hauled up from Earth. But NASA has also begun recycling some of those materials, such as waste plastic, to make new parts with the Refabricator, an advanced 3D printer installed in 2019.

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Manufacturing in space

You may be wondering why space explorers can’t simply bring everything they need with them. After all, that’s how the International Space Station was built decades ago – by hauling tons of prefabricated components from Earth.

But that’s impractical for building habitats on other worlds. Launching materials into space is incredibly expensive. Right now, every pound launched aboard a rocket just to get to low Earth orbit costs thousands of dollars. To get materials to the Moon, NASA estimates the initial cost at around US$500,000 per pound.

Still, manufacturing things in space is a challenge. In the microgravity of space, or the reduced gravity of the Moon or Mars, materials behave differently than they do on Earth. Decrease or remove gravity, and materials cool and recrystallize differently. The Moon has one-sixth the gravity of Earth; Mars, about two-fifths. Engineers and scientists are working now to adapt 3D printers to function in these conditions.

Using otherworldly soil

On alien worlds, rather than plastic or metal, 3D printers will use the natural resources found in these environments. But finding the right raw materials is not easy. Habitats on the Moon and Mars must protect astronauts from the lack of air, extreme temperatures, micrometeorite impacts and radiation.

Regolith, the fine, dusty, sandlike particles that cover both the lunar and Martian surfaces, could be a primary ingredient to make these dwellings. Think of the regolith on both worlds as alien dirt – unlike Earth soil, it contains few nutrients, and as far as we know, no living organisms. But it might be a good raw material for 3D printing.

My colleagues began researching this possibility by first examining how regular cement behaves in space. I am now joining them to develop techniques for turning regolith into a printable material and to eventually test these on the Moon.

But obtaining otherworldly regolith is a problem. The regolith samples returned from the Moon during the Apollo missions in the 1960s and 70s are precious, difficult if not impossible to access for research purposes. So scientists are using regolith simulants to test ideas. Actual regolith may react quite differently than our simulants. We just don’t know.

What’s more, the regolith on the Moon is very different from what’s found on Mars. Martian regolith contains iron oxide –that’s what gives it a reddish color – but Moon regolith is mostly silicates; it’s much finer and more angular. Researchers will need to learn how to use both types in a 3D printer. https://www.youtube.com/embed/J1TWlNWHrsw?wmode=transparent&start=0 See models of otherworldly habitats.

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Applications on Earth

NASA’s Moon-to-Mars Planetary Autonomous Construction Technology program, also known as MMPACT, is advancing the technology needed to print these habitats on alien worlds.

Among the approaches scientists are now exploring: a regolith-based concrete made in part from surface ice; melting the regolith at high temperatures, and then using molds to form it while it’s a liquid; and sintering, which means heating the regolith with concentrated sunlight, lasers or microwaves to fuse particles together without the need for binders.

Along those lines, my colleagues and I developed a Martian concrete we call MarsCrete, a material we used to 3D-print a small test structure for NASA in 2017.

Then, in May 2019, using another type of special concrete, we 3D-printed a one-third scale prototype Mars habitat that could support everything astronauts would need for long-term survival, including living, sleeping, research and food-production modules.

That prototype showcased the potential, and the challenges, of building housing on the red planet. But many of these technologies will benefit people on Earth too.

In the same way astronauts will make sustainable products from natural resources, homebuilders could make concretes from binders and aggregates found locally, and maybe even from recycled construction debris. Engineers are already adapting the techniques that could print Martian habitats to address housing shortages here at home. Indeed, 3D-printed homes are already on the market.

Meanwhile, the move continues toward establishing a human presence outside the Earth. Artemis III, now scheduled for liftoff in 2027, will be the first human Moon landing since 1972. A NASA trip to Mars could happen as early as 2035.

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But wherever people go, and whenever they get there, I’m certain that 3D printers will be one of the primary tools to let human beings live off alien land.

Sven Bilén, Professor of Engineering Design, Electrical Engineering and Aerospace Engineering, Penn State

This article is republished from The Conversation under a Creative Commons license. Read the original article.

NASA is set to offer live coverage of the much-anticipated return of its SpaceX Crew-9 mission from the International Space Station (ISS). The event will commence with preparations for the Dragon spacecraft’s hatch closure at 10:45 p.m. EDT on Monday, March 17.

In a proactive move, NASA and SpaceX convened on Sunday to evaluate the weather and splashdown conditions off Florida’s coast in preparation for the Crew-9 mission return. Thanks to favorable weather forecasts for Tuesday evening, March 18, mission managers are targeting an earlier return opportunity. This adjustment serves to allow the onboard crew ample time to complete their handover duties while also providing operational flexibility in anticipation of less favorable weather later in the week.

The Crew-9 mission features NASA astronauts Nick Hague, Suni Williams, and Butch Wilmore, along with Roscosmos cosmonaut Aleksandr Gorbunov. These skilled astronauts have been conducting a long-duration science expedition aboard the ISS and will bring back critical time-sensitive research to Earth.

As the launch nears, mission managers will continue to monitor weather conditions, which will play a pivotal role in the undocking process. Factors such as spacecraft readiness, recovery team preparedness, and sea states will all influence the timing and location of the splashdown. NASA and SpaceX will finalize and communicate the specific splashdown site as the Crew-9 return approaches.

For those interested in following along, you can watch the Crew-9 return activities live on NASA+. Additional viewing options, including various social media platforms, are also available. Schedule information can be found at NASA Live.

Here’s a timeline of the upcoming live coverage (all times EDT and subject to change):

Monday, March 17

• 10:45 p.m. – Hatch closing coverage begins on NASA+

Tuesday, March 18

• 12:45 a.m. – Undocking coverage begins on NASA+
• 1:05 a.m. – Undocking

Following the undocking coverage, there will be an audio-only feed. Assuming favorable weather conditions at the splashdown sites, continuous coverage will resume on NASA+ before the deorbit burn.

• 4:45 p.m. – Return coverage begins on NASA+
• 5:11 p.m. – Deorbit burn (approximate time)
• 5:57 p.m. – Splashdown (approximate time)

Following the splashdown, there will be a Return-to-Earth media conference at 7:30 p.m. on NASA+, featuring key participants, including:

• Joel Montalbano, Deputy Associate Administrator, NASA’s Space Operations Mission Directorate
• Steve Stich, Manager, NASA’s Commercial Crew Program
• Jeff Arend, Manager for Systems Engineering and Integration, NASA’s International Space Station Office
• Sarah Walker, Director, Dragon Mission Management, SpaceX

Mark your calendars and prepare to witness this exciting milestone in space exploration as NASA’s Crew-9 mission returns home!

Find full mission coverage, NASA’s commercial crew blog, and more information about the Crew-9 mission at:

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https://www.nasa.gov/commercialcrew

The science section of our news blog STM Daily News provides readers with captivating and up-to-date information on the latest scientific discoveries, breakthroughs, and innovations across various fields. We offer engaging and accessible content, ensuring that readers with different levels of scientific knowledge can stay informed. Whether it’s exploring advancements in medicine, astronomy, technology, or environmental sciences, our science section strives to shed light on the intriguing world of scientific exploration and its profound impact on our daily lives. From thought-provoking articles to informative interviews with experts in the field, STM Daily News Science offers a harmonious blend of factual reporting, analysis, and exploration, making it a go-to source for science enthusiasts and curious minds alike. https://stmdailynews.com/category/science/

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Moon Landing

In a significant milestone for space exploration, Firefly Aerospace’s Blue Ghost Mission 1 made a successful landing on the Moon at 3:34 a.m. EST on Sunday. Positioned near the volcanic feature of Mons Latreille within Mare Crisium, a vast basin exceeding 300 miles in diameter, this event marks a pivotal moment in NASA’s initiatives concerning lunar exploration.

This successful moon landing represents the first delivery under NASA’s Commercial Lunar Payload Services (CLPS) initiative for Firefly Aerospace, and it adds another achievement to the Artemis campaign aimed at returning humans to the Moon. The Blue Ghost lander now rests upright and stable on the lunar surface, ready to begin its suite of scientific operations.

The Blue Ghost craft is carrying ten cutting-edge NASA science and technology instruments designed to perform a variety of functions over approximately one lunar day, which translates to about 14 Earth days. Acting Administrator Janet Petro highlighted the importance of this mission, stating, “This incredible achievement demonstrates how NASA and American companies are leading the way in space exploration for the benefit of all.” The lessons learned from this mission will enhance future safety protocols for scientific exploration on the Moon and beyond.

Following its launch from NASA’s Kennedy Space Center on January 15, the Blue Ghost traveled over 2.8 million miles. During this journey, it downlinked more than 27 gigabytes of data while conducting several critical science operations. One notable achievement included signal tracking from the Global Navigation Satellite System (GNSS) at a record distance of 246,000 miles, validating the potential for similar positioning systems to be used effectively on the Moon.

Nicky Fox, associate administrator for science at NASA Headquarters, emphasized the significance of this mission in laying the groundwork for future human presence on the Moon: “The science and technology we send to the Moon now helps prepare the way for future NASA exploration and long-term human presence to inspire the world for generations to come.”

The instruments aboard the Blue Ghost will perform a variety of tasks during their lunar surface operations, including testing advanced drilling technology, collecting regolith samples, and developing lunar dust mitigation strategies. The insights gained from these experiments will contribute to our understanding of how space weather and cosmic forces interact with Earth.

As operations continue, the team intends to capture stunning imagery of the lunar sunset and investigate the behaviors of lunar dust during dusk conditions—an occurrence previously documented by Apollo 17 astronaut Eugene Cernan. Following the lunar sunset, the lander will remain functional for several hours into the lunar night.

Firefly Aerospace’s CEO, Jason Kim, expressed gratitude to NASA for the partnership and outlined the significance of this mission. “Blue Ghost’s successful Moon landing has laid the groundwork for the future of commercial exploration across cislunar space,” he stated, adding, “We’re now looking forward to more than 14 days of surface operations to unlock even more science data that will have a substantial impact on future missions to the Moon and Mars.”

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In total, five companies have been awarded 11 lunar deliveries under the CLPS initiative, propelling the lunar economy forward with over 50 instruments being sent to various lunar locations, including the lunar South Pole. With a cumulative maximum contract value of $2.6 billion through 2028, the CLPS initiative is set to revolutionize how we explore and utilize the Moon’s resources.

As we celebrate this monumental achievement, it is clear that the collaboration between NASA and companies like Firefly Aerospace is paving the way for a new era of exploration, promising exciting discoveries that will benefit our understanding of the cosmos and our own planet for generations to come.

Learn more about NASA’s CLPS initiative at:

https://www.nasa.gov/clps

The science section of our news blog STM Daily News provides readers with captivating and up-to-date information on the latest scientific discoveries, breakthroughs, and innovations across various fields. We offer engaging and accessible content, ensuring that readers with different levels of scientific knowledge can stay informed. Whether it’s exploring advancements in medicine, astronomy, technology, or environmental sciences, our science section strives to shed light on the intriguing world of scientific exploration and its profound impact on our daily lives. From thought-provoking articles to informative interviews with experts in the field, STM Daily News Science offers a harmonious blend of factual reporting, analysis, and exploration, making it a go-to source for science enthusiasts and curious minds alike. https://stmdailynews.com/category/science/

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