In-Situ Regolith Processing for Additive Manufacturing
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Solution Overview
Problem
Transporting building materials to off-planet locations is prohibitively expensive, complex, and time-consuming, limiting the feasibility of space exploration and settlement due to the need for in-situ resource utilization and efficient waste management in microgravity environments.
Innovation Solution
The use of in-situ materials, such as lunar regolith or Martian soil, for additive manufacturing to create structures, heat shields, and sample return containers, reducing the need for mass and volume to be launched from Earth, and enabling the creation of infrastructure and resources on-site using locally sourced materials processed into conditioned feedstock.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If building materials are transported from Earth to off-planet locations, then construction capability is provided, but cost, complexity and time consumption increase prohibitively
Solution Approach 1:
The patent implements self-service by enabling the space mission to construct its own infrastructure using locally available regolith materials rather than relying on materials transported from Earth. The system collects and processes in-situ resources to create construction feedstock, allowing the mission to build habitats and structures autonomously at the destination location.
Solution Approach 2:
The patent applies parameter changes by transforming regolith materials through processing operations that alter their physical and chemical properties. The regolith is converted from its natural state into conditioned feedstock suitable for additive manufacturing, changing parameters such as particle size, composition, and mechanical properties to enable construction applications.
2Ease of operation
If equipment is hauled from Earth to space missions, then operational capability is enabled, but launch cost exceeds $1,000 per kilogram
Solution Approach 1:
The system enables self-service by equipping the space mission with on-site resource processing and additive manufacturing capabilities. Instead of relying on expensive Earth-launched equipment, the mission uses locally processed regolith to manufacture necessary components and structures, dramatically reducing the mass that must be launched from Earth.
Solution Approach 2:
The patent applies preliminary action by processing regolith into conditioned feedstock in advance of when construction materials are needed. The material is collected, processed and stored in a ready-to-use state, enabling rapid manufacturing of construction elements without requiring repeated Earth supply missions.
3Productivity
If in-situ materials are collected and processed into feedstock, then construction materials are available locally, but processing time and energy are required
Solution Approach 1:
The system applies preliminary action by collecting and processing regolith into conditioned feedstock before actual construction operations begin. The material is prepared in advance and stored in readiness, so that when construction is needed, the feedstock is already available and requires minimal additional processing, reducing overall project timeline.
Data Source
AI summary
Methods of collecting in-situ materials on a celestial body for return to Earth or another location and associated devices are described. These devices and methods facilitate collection of samples and creation of portions of the return spacecraft via an additive manufacturing device contained within the lander craft. The additive manufacturing device is configured to produce portions of the return spacecraft (e.g., sample return container, spacecraft structure, heat shield) and may also be configured to place samples within the spacecraft for return and analysis.