Madhu Thangavelu

Advances in Contour Crafting Technology for Extraterrestrial Settlement Infrastructure Buildup

Several unique systems including the Lunar Electric Rover, the unpressurized Chariot rover, the versatile light-weight crane and Athlete cargo transporter as well as the habitat module mockups and a new generation of spacesuits are undergoing coordinated tests at NASA’s facility for Desert Research and Test Studies (D-RATS). A synergetic simulation plan is proposed for utilizing these maturing systems coupled with a unique, patented robotic fabrication technology called Contour Crafting, tailored for swift and reliable lunar infrastructure development. Landing pads, roads, shade walls and thermal and micrormeteoritic shield and other unpressurized structures that make up a majority of the initial lunar settlement infrastructure may be built using this technology, fully utilizing InSitu Resource Utilization(ISRU) strategy. The intent is to increase astronaut safety, improve buildup performance, ameliorate lunar dust interference and concerns, and reduce time-tocommission, all in an economic manner.

Contour Crafting Simulation Plan for Lunar Settlement Infrastructure Build-Up

Economically viable and reliable building systems and tool sets are being sought, examined and tested for extraterrestrial infrastructure buildup. This project focused on a unique architecture weaving the robotic building construction technology with designs for assisting rapid buildup of initial operational capability Lunar and Martian bases. The project aimed to study new methodologies to construct certain crucial infrastructure elements in order to evaluate the merits, limitations and feasibility of adapting and using such technologies for extraterrestrial application. Current extraterrestrial settlement buildup philosophy holds that in order to minimize the materials needed to be flown in, at great transportation costs, strategies that maximize the use of locally available resources must be adopted. Tools and equipment flown as cargo from Earth are proposed to build required infrastructure to support future missions and settlements on the Moon and Mars.

Robotic Construction by Contour Crafting: The Case of Lunar Construction

Contour Crafting is a digitally controlled construction process invented by Professor Behrokh Khoshnevis that fabricates components directly from computer models, using layered fabrication technology. By obviating the need for formwork used in traditional concrete construction, CC can reduce costs and construction times significantly. The technique has great potential as a robotic form of construction reliant on relatively minimal human labor as a form of construction in relatively hazardous environments, such as the Moon with its radiation levels that can prove highly damaging. Current research funded by NASA has been exploring the potential for using CC on the Moon to build structures making use of readily available regolith that is found in great abundance on the surface of the Moon. This article offers an overview of this research and evaluates the merits of using CC on the Moon.

Preliminary Infrastructure Development for Altair Sortie Operations

*† NASA’s Exploration Systems Architecture Study ( ESAS) rep ort envisions humans returning to the Moon in the 2020 timeframe. However, many factors still need to be addressed in depth. They include site selection, materials, and design of inhabitable and survivable infrastructure elements. One of the most important issues dealing with a manned return mission to the Moon is lunar dust. Dust suppression is a critical issue with regard to Altair operations as well as surface vehicles in the proximity of the habitat. Dust and debris thrown up by vehicles can also degrad e exposed payloads such as telescope elements and photovoltaic arrays. This paper explores several architectural concepts relating to developing essential preliminary infrastructure for humans on the lunar surface during the first several missions. Concept s discussed include certain selection criteria aspects for lunar habitat location as well as a variety of architectural elements, which can ameliorate the effects of lunar dust during Altair operations and routine surface vehicle movement around the primar y lunar settlement. Specifically, these elements include a microwave sintered landing zone around a hard, paved and topped landing pad for repeated service use, inflatable structures for blast aprons, a light rail system with pallet, winch and gantry suppo rt for lander and payload transport from landing pad to hangar or habitat location, a hard, topped dust -free platform on which to erect the habitat and allied structures, and a built -up access road from the habitat area to the hangar and the landing pad. A n emergency exit route from habitat to a standby escape vehicle is also depicted as well as a dust monitoring system and a dust cleaning rover attachment is suggested as well.

Bio-Regenerative Life Support System Development for Lunar/Mars Habitats

Bio-regenerative Life Support Systems (BLSS) uses biological processes to support an astronaut crew, and includes atmosphere revitalization, water recycling, food production, and organic waste recycling. The University of Arizona Controlled Environment Agriculture Center (UA-CEAC), Systems and Industrial Engineering Department, Sadler Machine Co. (USA) and Italian collaborators, Thales Alenia Space Italia (TAS-I), Aero-Sekur, SpA, and University of Naples Federico II are developing BLSS for future Lunar/Mars surface missions. Current efforts at UA-CEAC include operation of four BLSS Lunar Greenhouse (LGH) Prototype Units with the primary purpose of demonstrating poly-culture production of food crops in a semi-closed gaseous cycle, and preliminary efforts of waste DWEComposting, Solar Concentrating Plant Lighting/Power System, and System Monitoring/Telepresence Support. TAS-I, the University of Naples, and Aero-Sekur BLSS efforts in Italy include operation of Recyclab, the EDEN chamber, and the development of space plant growth chambers. UA-CEAC efforts are supported by NASA Ralph Steckler Phase II Space Grant while the Italian collaborators have been supported by ESA, ASI, and regional, and internal sources. Based on NASA crop production area estimates the LGH with its four modules will support a four person crew with 100% of their water/atmosphere

The Exploration of Mars: Crew Surface Activities

Surface activities of the first Mars mission crew, as suggested in phase I of the NASA HEDS reference mission, are discussed in this paper. The HEDS reference mission calls for a two phased approach. In phase I, humans supported by robotic systems will explore the Martian surface, collect and analyze geologic, geophysical, and meteorological data, search for potential permanent base sites, and conduct technology verification experiments. In phase II, a Mars base site will be selected, and the building of a permanent human base will be initiated. In this report two complementary architectures are portrayed. First, a permanent base for 3-6 people consisting of an ISRU unit, two nuclear power systems, a green house, and inflatable habitats and laboratories, built inside adobe structures. Second, a reusable, and resupplyable methane propelled very long range type traverse vehicle capable of collecting and analyzing data, and repairing and deploying scientific payloads during its planned 150 days 4800 km traverse. The very long range traverse vehicle will carry smaller rovers, crawlers, blimps, and an air drill capable of quickly reaching depths beyond 100m. The report presents a global vision of human activities on the surface of Mars at a programmatic level. It consists of several vignettes called “concept architectures” We speculate that these activities will facilitate a phase I Mars exploration architecture.

Architectural Concepts Employing Co-Robot Strategy and Contour Crafting Technologies for Lunar Settlement Infrastructure Development

A lunar base development strategy that simultaneously employs robots and humans in a safe, effective and economic manner is depicted in this USC School of Architecture and School of Engineering design project done in the Spring of 2012, under the banner of the graduate Moon Studio. Real time telerobotic systems are proposed as an economically viable strategy for lunar base buildup operations. Co-robots are robotic systems designed and operated in real time using telerobotics, to directly support a variety of complex activities which require human supervision. Use of co-robots will allow real time correction of anomalies, separate and protect humans from a number of risky EVA scenarios, and speed up building processes. The strategy is also applicable for complex construction projects here on Earth, especially in the erection and deployment of critical structures, forward base camps and outposts, where human exposure to building activity is deemed hazardous. Elements depicted include the design of a permanent lunar landing and lift off pad for repeated crew and cargo/logistics sorties, a transport infrastructure linking the landing pad to the habitat zone, a dust free platform to erect habitat elements, components and configuration of an early phase lunar habitat for six crew members, and a variety of design elements to ameliorate lunar dust effects in the vicinity of this complex. The lunar base complex is seen as the critical foothold for developing a larger permanent settlement. Some architectural concepts developed in the graduate Moon Studio that propose various lunar settlements and activities are depicted. Eventually, it is the aim of this project to utilize this technology on a large scale here on Earth for complex building projects as well as economic buildup of cities and projects in remote or hazardous regions of the globe using humans primarily in a supervisory role, thereby reducing hard labor, associated fatigue and accidents, while improving overall efficiency of the building process.

LunarSS and Kaijuu: Inspiring the Future

Students in the US are lacking interest in Math and Science, as expressed in educational statistics. University graduates in Science and Engineering, especially in Astronautics and Aerospace related education, continue to decline. If the NASA space program or even the private industry do not succeed in inspiring the future generation, all efforts and the prized US legacy of these programs will be lost to other countries, and consequently will slow humanity’s progress in technology and knowledge of our Universe in which Space Exploration and space activities play a critical role. Astronomers today, employing World Wide Web technology, routinely use observatories around the world, without being on-site. Several new initiatives like Google Earth, Google Sky and Virtual Telescope now allow users to remotely access and operate facilities and download requested information for further study and analysis. The Lunar Space Scope Project Concept (LunarSS) proposes to extend this remote operations and data gathering technology to the University and the K-12 school student using lunar observatories. It promises to engage them through the internet to make their own astronomy observations or test data to be analyzed right in their classroom:

Human Space Activities : The Next Fifty Years

Critical concepts explored in the fall 2006 Space Architecture seminar conducted at the USC School of Architecture are presented. They include the melding of space and commercial aeronautical applications using trans-atmospheric vehicles for rapid point-topoint travel, low Earth Orbiting Hotels and transit lounges and the development of lunar bases including an United Nations facility on the Moon. Multiple Membrane Inflatable Structures will offer added protection against space hazards and advanced spacesuits will eliminate the need for pre-breathing. Innovative methods to land large payloads on the Moon are proposed. Solar photovoltaic towers for power generation is depicted and tensegrity structures and their applications for space are discussed. Introduction In the fall of 2006, graduate students in the School of Architecture at USC pondered the future of human spaceflight over the next fifty years. The five week, 15 hour seminar was intended as an introduction to human space activity and participants were exposed to poignant missions and technologies that have shaped space exploration. It included a curator guided tour of the Los Angeles Aerospace Museum that houses historical memorabilia. [See Figure 1] Each participant then picked a topic of interest relating to human space activity and visualized a concept, extrapolating on human space activity as it is today. AIAA Space 2007 Conference, September 2007, Long Beach, California Arch 599 Graduate Seminar in Human Space Exploration, Fall 2006, School of Architecture, University of Southern California. Los Angeles, CA 90089 Figure 1. USC graduate architecture students in front of an Apollo capsule, a historic artifact from the Apollo-Soyuz mission, at the Los Angeles Aerospace Museum. The aim of the course was to provide just enough information to civil architecture students, that they might look into what the future holds, from an architectural perspective. Technical feasibility was not stressed as much as the ability to project imaginative, appealing, “out of the box” visions, with the confidence that fine engineers at NASA and the industry would find innovative technological solutions to execute projects that made programmatic and economic sense while being an awe-inspiring magnet for all segments of humanity and not just for those scientists and technologists, who have a direct, invested interest in this arena of bold and daring human endeavor. Following are synopses of some of the concepts that evolved and were presented to a group of reviewers who included aerospace engineers, test pilots, space architects, toy designers, and USC architecture faculty members. [See Figure 2] Figure 2. USC graduate students presented their visions to a group of reviewers who included aerospace engineers, test pilots, space architects, toy designers, and USC architecture faculty members. A Lunar Polar Community for 100 people Mons Malapert in the south polar region of the Moon was proposed as a preferred location because it had direct visual link to the Earth disc in the horizon and plenty of solar access as well as depressed, cratered areas in perpetual shade. Vertically integrated modular habitats could form the core of settlements. Such concepts have been explored in the past by Peter Cook, and more recently in the works of Kikutake, Piano and Rogers and Calatrava among others. Tall tower structures within craters would be viable since the Moon has no lateral wind loads imposed by any atmosphere and lunar quakes are quite infrequent and of slight magnitude. Sunlight arriving at shallow angles in the polar regions may be directed as needed using reflectors and diffusers. Partial gravity would impact crew movement and posture and in turn affect the plan and volumes of habitable spaces. Higher ceilings are recommended for interiors. Innovative ways to move around the habitat are proposed and specially designed heavy boots are envisioned for anchoring crew for certain tasks. [See Figure 3] Figure 3. Tall tower structures within craters would be viable since the Moon has no lateral wind loads imposed by any atmosphere and lunar quakes are quite infrequent and of slight magnitude. Sunlight arriving at shallow angles in the polar regions may be directed as needed using reflectors and diffusers. Lunar gravity which is 1/6 of Earth’s, would impact crew movement and posture and in turn affect the plan and volumes of habitable spaces. Higher ceilings are recommended for interiors. Innovative ways to move around the habitat are proposed and specially designed heavy boots are envisioned for anchoring crew for certain tasks. Lunar Solar Power Tower Large photovoltaic curtains may be hung on tall tower structures to convert sunlight directly into electric power. These curtains would also keep the structure at constant temperature, thereby reducing the effects of thermal expansion and associated deflection and buckling. The curtains would rotate synchronously with the sun and provide ample power for the settlement. A power grid using several towers dispersed over a large region may be evolved over time and microwave beaming technology could be employed for hooking up the tower network. [See Figure 4] Figure 4. Concepts for Solar Power Towers and Microwave energy beaming Large Scale Lunar Agriculture The ability to raise crops and grow food is essential for any long term, sustainable habitation. Bases in the Antarctica offer insight into how this might be accomplished. Advances in Aeroponics, Hydroponics and Aquaponics will enable lunar food production. Genetically modified, high yielding crops may be grown and lunar regolith minerals may be used to augment nutrients and materials for supporting root growth as well as for cultivation. The Crater based Large Lunar Cargo Lander Facility An idea to absorb landing shock using suitably sized craters fitted with shock absorbing material is depicted. The proposal is to use such a facility to land bulk cargo such as raw materials, water and food. Since raw cargo can withstand several gs during landing without difficulty, the proposed strategy is to target the bulk lander cargo into the prepared crater during final descent stage of trajectory and let the payload impact the site without use of final touchdown propulsion. The concept envisions a crater landing facility that uses shock absorbing materials which is reusable after minimal preparation. Lunar Crew Escape Vehicle Using the Crew Exploration Vehicle(CEV) capsule in the NASA Constellation program as baseline, this concept explored the possibility of using the CEV as a crew escape/rescue vehicle. Tensegrity Structure The twentieth century philosopher, inventor and visionary architect Richard Buckminster Fuller, who coined the term spaceship Earth, was also responsible for several designs and concepts that emphasized the need to use resources in a frugal and responsible manner. Along with student Kenneth Snelson, one such exploration led to the development of tensile structures that he called tensegrity(tensile+integrity) structures. [See Figure 5] These structures, composed of taut cables and struts could be used for a variety of space related activity. By employing microelectromechanical system technology, it should be possible to design and commission dynamic space structures which exploit the structural flexibility offered by cable movement across strut nodes. Figure 5 Examples of Tensegrity Structures where struts in compression are supported by cables in tension. Note that struts do not touch each other. Inflatable Structures Inflatable membrane structures such as blimps, tires, bellows, balloons and play structures like moon bouncers and even habitats have been commissioned on Earth for many decades. The idea that such structures may be employed for building spacious dwellings in space is not new. NASA’s Transhab project and test modules like the Genesis 1 and 2, in Earth orbit now, offer promise to provide large pressurized volumes within which aesthetically pleasing and functional spaces may be created. [See Figure 6a] In the multiple membrane inflatable system that was explored by a participant, A. Merchant, by inflating membrane within membrane, it is possible to produce, segmented, complex shapes and volumes. [See Figure 6b] Such partitions are explored in the Arcology(architecture+ecology) concepts and designs of visionary architect Paolo Soleri. Multiple membranes also provide additional safety in the event of accidental rupture, improves radiation protection, provides additional shielding against micrometeritic and debris hazards and helps to build up pressure gradients so that the exterior membrane can be at a much lower pressure than the habitable interior membrane. Figure. 6a. Examples of Inflatable structures include the Goodyear Blimp, NASA’s Transhab module and Bigelow’s Genesis module now in Earth orbit. Figure 6b. An exploration of multiple membrane inflatable structure shows that interesting spaces and volumes could be created. Differential pressurization is possible and multiple bladders also enhance particle radiation protection and safety in case of accidental rupture and subsequent sudden decompression effects. United Nations Summit Headquarters on the Moon One of the tasks assigned to the class was to look at concepts above and beyond the establishment of scientific and technology demonstration platforms on the Moon. The concept for establishing a United Nations Summit Headquarters on the Moon was proposed. A lunar site would truly provide a stimulating setting from which the world’s nations might better ponder the actions of humanity, and their consequences, on our fragile planet. Advanced EVA suit As lunar settlement activities gain momentum, EVA will become routine for supervisory as well as maintenance and repair functions which are not suited for robotic intervention. As missions grow more complex and delicate, and those requiring short interval responses