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Develop and enable the technologies, materials, and processes required to provide affordable, sustainable on-demand manufacturing, recycling, and repair during Exploration Missions.

Disruptive technologies are unique in that they spawn other new technologies and applications as they grow. These activities are usually preceded by the question, "What If?" For example, "What if we could use an emerging technology and in-situ materials to promote exploration on the Moon or Mars, and then use that same technology to keep our troops out of harm's way and/or help the worlds' homeless?" This question allows us to flip the mindset of "how can people create more valuable innovation?" to "how can innovation create more valuable people?." This approach allows us to view augmented human labor as an inclusive opportunity, not a threat. The discipline of Additive Construction is growing rapidly due to the flexibility, speed, safety and logistics benefits offered as compared to standard construction techniques. Additive construction is a disruptive technology in that it employs the principles of additive manufacturing on a human habitat structure scale. Developed initially for emergency management and disaster relief applications, additive construction has now grown into military infrastructure and planetary (Moon and Mars) surface infrastructure applications as well. Additive Construction with Mobile Emplacement (ACME) is a NASA technology development project that seeks to demonstrate the feasibility of constructing shelters for human crews, and other surface infrastructure, on the Moon or Mars for a future human presence. The ACME project will allow, for the first time, the 3-dimensional printing of surface structures on planetary bodies using local materials for construction, thereby tremendously reducing launch and transportation mass and logistics. Some examples of infrastructure that could be constructed using robotic additive construction methods are landing pads, rocket engine blast protection berms, roads, dust free zones, equipment shelters, habitats and radiation shelters. Terrestrial applications include the development of surface structures using Earth-based materials for emergency response, disaster relief, general construction, and housing at all economic levels. This paper will describe the progress made by the NASA ACME project with a focus on prototypes and full scale additive construction demonstrations using both Portland cement concrete and other indigenous material mixtures. Rationale for the use of additive construction for both terrestrial and planetary applications will be explored and a thorough state-of-the-art of additive construction techniques will be presented. An evolutionary history of NASA's additive construction development efforts, dating back to 2004, will be included. The paper will then step through a series of trade studies performed to inform key processing and design decisions in the development of the full-scale ACES-3 system developed by NASA and the Jacobs Space Exploration Group for the U.S. Army Corps of Engineers (USACE) Construction Engineers Research Laboratory (CERL) in Champaign, IL. The selection of aggregate and binders, based on in-situ materials, will also be presented and discussed

Lunar simulants are terrestrial materials that mimic aspects of lunar regolith for testing of technology that would interact with lunar surface material. The goal of simulants is mission risk reduction by providing confidence, through testing with simulants, that a technology will perform as designed on the lunar surface. Lunar simulants are often used in education and outreach activities to increase public knowledge about lunar surface materials and to inspire the next generation of space explorers.

For long-duration missions on other planetary bodies, the use of in situ materials will become increasingly critical. As human presence on these bodies expands, so must the breadth of the structures required to accommodate them including habitats, laboratories, berms, radiation shielding for natural radiation and surface reactors, garages, solar storm shelters, greenhouses, etc. Planetary surface structure manufacturing and assembly technologies that incorporate in situ resources provide options for autonomous, affordable, pre-positioned environments with radiation shielding features and protection from micrometeorites, exhaust plume debris, and other hazards. The ability to use in-situ materials to construct these structures will provide a benefit in the reduction of up-mass that would otherwise make long-term Moon or Mars structures cost prohibitive. The ability to fabricate structures in situ brings with it the ability to repair these structures, which allows for the self-sufficiency and sustainability necessary for long-duration habitation. Previously, under the auspices of the MSFC In-Situ Fabrication and Repair (ISFR) project and more recently, under the jointly-managed MSFC/KSC Additive Construction with Mobile Emplacement (ACME) project, the MSFC Surface Structures Group has been developing materials and construction technologies to support future planetary habitats with in-situ resources. One such additive construction technology is known as Contour Crafting. This paper presents the results to date of these efforts, including development of novel nozzle concepts for advanced layer deposition using this process. Conceived initially for rapid development of cementitious structures on Earth, it also lends itself exceptionally well to the automated fabrication of planetary surface structures using minimally processed regolith as aggregate, and binders developed from in situ materials as well. This process has been used successfully in the fabrication of construction elements using lunar regolith simulant and Mars regolith simulant, both with various binder materials. Future planned activities will be discussed as well.

For long-duration missions on other planetary bodies, the use of in-situ materials will become increasingly critical. As man's presence on these bodies expands, so must the breadth of the structures required to accommodate them including habitats, laboratories, berms, radiation shielding for natural radiation and surface reactors, garages, solar storm shelters, greenhouses, etc. Planetary surface structure manufacturing and assembly technologies that incorporate in-situ resources provide options for autonomous, affordable, pre-positioned environments with radiation shielding features and protection from micrometeorites, exhaust plume debris, and other hazards. This is important because gamma and particle radiation constitute a serious but reducible threat to long-term survival of human beings, electronics, and other materials in space environments. Also, it is anticipated that surface structures will constitute the primary mass element of lunar or Martian launch requirements. The ability to use in-situ materials to construct these structures will provide a benefit in the reduction of up-mass that would otherwise make long-term Moon or Mars structures cost prohibitive. The ability to fabricate structures in situ brings with it the ability to repair these structures, which allows for self-sufficiency necessary for long-duration habitation. Previously, under the auspices of the MSFC In Situ Fabrication and Repair (ISFR) project and more recently, under the joint MSFC/KSC Additive Construction with Mobile Emplacement (ACME) project, the MSFC Surface Structures Group has been developing materials and construction technologies to support future planetary habitats with in situ resources. One such technology, known as Contour Crafting (additive construction), is shown in Figure 1, along with a typical structure fabricated using this technology. This paper will present the results to date of these efforts, including development of novel nozzle concepts for advanced layer deposition using the Contour Crafting process. This process, conceived initially for rapid development of cementitious structures on Earth, also lends itself exceptionally well to the automated fabrication of planetary surface structures using minimally processed regolith as aggregate, and imported binder material or binders developed from in situ materials. This process has been used successfully in the fabrication of construction elements using lunar regolith simulant and Mars regolith simulant, both with various binder materials. These binder materials have resulted from extensive evaluation and include both "imported" binder materials that might be launched from Earth as well as some binder materials that can theoretically also be derived from existing regolith materials. They were chosen to 1) reduce penetrating radiation as much as possible, primarily with hydrogen-bearing polymers, 2) attempt to provide an air-tight structure, 3) sufficiently mix and adsorb to regolith grains for strength, 4) maximize tolerance to day-night thermal cycling, 5) possibly increase electrical conductivity to dissipate any accumulated static charge, and 6) ease their application on planetary surfaces (specifically, the accommodation of reduced atmosphere and lack of heat sinks). Some of these materials have been tested with respect to radiation mitigation, micrometeorite resistance, and resistance to larger, slower-traveling pieces of regolith impinging on the surface, simulating nearby launch and landing activities. Conceptual designs for a Continuous Feedstock Delivery/Mixing System (CFDMS) will also be presented and future planned activities will be discussed as well.

The National Aeronautics and Space Administration (NASA) has a long term strategy to fabricate components and equipment on-demand for manned missions to the Moon, Mars, and beyond. To support this strategy, NASA and Made in Space, Inc. are developing the 3D Printing In Zero-G payload as a Technology Demonstration for the International Space Station. The 3D Printing In Zero-G experiment will be the first machine to perform 3D printing in space. The greater the distance from Earth and the longer the mission duration, the more difficult resupply becomes; this requires a change from the current spares, maintenance, repair, and hardware design model that has been used on the International Space Station up until now. Given the extension of the ISS Program, which will inevitably result in replacement parts being required, the ISS is an ideal platform to begin changing the current model for resupply and repair to one that is more suitable for all exploration missions. 3D Printing, more formally known as Additive Manufacturing, is the method of building parts/ objects/tools layer-by-layer. The 3D Print experiment will use extrusion-based additive manufacturing, which involves building an object out of plastic deposited by a wire-feed via an extruder head. Parts can be printed from data files loaded on the device at launch, as well as additional files uplinked to the device while on-orbit. The plastic extrusion additive manufacturing process is a low-energy, low-mass solution to many common needs on board the ISS. The 3D Print payload will serve as the ideal first step to proving that process in space. It is unreasonable to expect NASA to launch large blocks of material from which parts or tools can be traditionally machined, and even more unreasonable to fly up specialized manufacturing hardware to perform the entire range of function traditionally machining requires. The technology to produce parts on demand, in space, offers unique design options that are not possible through traditional manufacturing methods while offering cost-effective, high-precision, low-unit on-demand manufacturing. Thus, Additive Manufacturing capabilities are the foundation of an advanced manufacturing in space roadmap.

Long-duration surface missions to the Moon or Mars will require life support systems that maximize resource recovery to minimize resupply from Earth. To address this need, NASA previously proposed a Series-Bosch (S-Bosch) oxygen recovery system, based on the Bosch process, which can theoretically recover 100% of the oxygen from metabolic carbon dioxide. Bosch processes have the added benefits of the potential to recover oxygen from atmospheric carbon dioxide and the use of regolith materials as catalysts, thereby eliminating the need for catalyst resupply from Earth. In 2012, NASA completed an initial design for an S-Bosch development test stand that incorporates two catalytic reactors in series including a Reverse Water-Gas Shift (RWGS) Reactor and a Carbon Formation Reactor (CFR). In 2013, fabrication of system components, with the exception of a CFR, and assembly of the test stand was initiated. Stand-alone testing of the RWGS reactor was completed to compare performance with design models. Continued testing of Lunar and Martian regolith simulants provided sufficient data to design a CFR intended to utilize these materials as catalysts. Finally, a study was conducted to explore the possibility of producing bricks from spent regolith catalysts. The results of initial demonstration testing of the RWGS reactor, results of continued catalyst performance testing of regolith simulants, and results of brick material properties testing are reported. Additionally, design considerations for a regolith-based CFR are discussed.

The National Aeronautics and Space Administration (NASA) has a long term strategy to fabricate components and equipment on‐demand for manned missions to the Moon, Mars, and beyond. To support this strategy, NASA and Made in Space, Inc. are developing the 3D Printing In Zero‐G payload as a Technology Demonstration for the International Space Station (ISS). The 3D Printing In Zero‐G experiment ('3D Print') will be the first machine to perform 3D printing in space. The greater the distance from Earth and the longer the mission duration, the more difficult resupply becomes; this requires a change from the current spares, maintenance, repair, and hardware design model that has been used on the International Space Station (ISS) up until now. Given the extension of the ISS Program, which will inevitably result in replacement parts being required, the ISS is an ideal platform to begin changing the current model for resupply and repair to one that is more suitable for all exploration missions. 3D Printing, more formally known as Additive Manufacturing, is the method of building parts/objects/tools layer‐by‐layer. The 3D Print experiment will use extrusion‐based additive manufacturing, which involves building an object out of plastic deposited by a wire‐feed via an extruder head. Parts can be printed from data files loaded on the device at launch, as well as additional files uplinked to the device while on‐orbit. The plastic extrusion additive manufacturing process is a low‐energy, low‐mass solution to many common needs on board the ISS. The 3D Print payload will serve as the ideal first step to proving that process in space. It is unreasonable to expect NASA to launch large blocks of material from which parts or tools can be traditionally machined, and even more unreasonable to fly up multiple drill bits that would be required to machine parts from aerospace‐grade materials such as titanium 6‐4 alloy and Inconel. The technology to produce parts on demand, in space, offers unique design options that are not possible through traditional manufacturing methods while offering cost-effective, high‐precision, low‐unit on‐demand manufacturing. Thus, Additive Manufacturing capabilities are the foundation of an advanced manufacturing in space roadmap. The 3D Printing In Zero‐G experiment will demonstrate the capability of utilizing Additive Manufacturing technology in space. This will serve as the enabling first step to realizing an additive manufacturing, print‐on‐demand "machine shop" for long‐duration missions and sustaining human exploration of other planets, where there is extremely limited ability and availability of Earth‐based logistics support. Simply put, Additive Manufacturing in space is a critical enabling technology for NASA. It will provide the capability to produce hardware on‐demand, directly lowering cost and decreasing risk by having the exact part or tool needed in the time it takes to print. This capability will also provide the much‐needed solution to the cost, volume, and up‐mass constraints that prohibit launching everything needed for long‐duration or long‐distance missions from Earth, including spare parts and replacement systems. A successful mission for the 3D Printing In Zero‐G payload is the first step to demonstrate the capability of printing on orbit. The data gathered and lessons learned from this demonstration will be applied to the next generation of additive manufacturing technology on orbit. It is expected that Additive Manufacturing technology will quickly become a critical part of any mission's infrastructure.

Future engineering of structures and equipment on the lunar surface requires significant understanding of particle characteristics of the lunar regolith. Nearly all sediment characteristics are influenced by particle shape; therefore a method of quantifying particle shape is useful both in lunar and terrestrial applications. We have created a method to quantify particle shape, specifically for lunar regolith, using image processing. Photomicrographs of thin sections of lunar core material were obtained under reflected light. Three photomicrographs were analyzed using ImageJ and MATLAB. From the image analysis measurements for area, perimeter, Feret diameter, orthogonal Feret diameter, Heywood factor, aspect ratio, sieve diameter, and sieve number were recorded. Probability distribution functions were created from the measurements of Heywood factor and aspect ratio.

Future manned missions to deep space or planetary surfaces will undoubtedly incorporate highly robust, efficient, and regenerable life support systems that require minimal consumables. To meet this requirement, NASA continues to explore a Bosch-based carbon dioxide reduction system to recover oxygen from CO2. In order to improve the equivalent system mass of Bosch systems, we seek to design and test a "Series Bosch" system in which two reactors in series are optimized for the two steps of the reaction, as well as to explore the use of in situ materials as carbon deposition catalysts. Here we report recent developments in this effort including assembly and initial testing of a Reverse Water-Gas Shift reactor (RWGSr) and initial testing of two gas separation membranes. The RWGSr was sized to reduce CO2 produced by a crew of four to carbon monoxide as the first stage in a Series Bosch system. The gas separation membranes, necessary to recycle unreacted hydrogen and CO2, were similarly sized. Additionally, we report results of preliminary experiments designed to determine the catalytic properties of Martian regolith simulant for the carbon formation step.

The National Aeronautics and Space Administration (NASA) has a long term strategy to fabricate components and equipment on-demand for manned missions to the Moon, Mars, and beyond. To support this strategy, NASA's Marshall Space Fligth Center (MSFC) and Made in Space, Inc. are developing the 3D Printing In Zero-G payload as a Technology Demonstration for the International Space Station (ISS). The 3D Printing In Zero-G experiment ('3D Print') will be the frst machine to perform 3D printing in space.

The specialist literature about the lunar regolith is massive. It is also highly focused on specific topics and effectively impenetrable to most non-geologists. Both characteristics of the literature present substantial hurdles to scientists and engineers interested in the regolith In the author's experience it neither surprising or unusual to find serious misconceptions about lunar-type materials outside of the lunar research community. Education of professionals who are non-geologists but interested in the regolith is impeded by a lack of some basic resources. One asset that has been missing is simply detailed images of the regolith "soil". While a few websites offer imagery of specific features, these are of course selected to illustrate specific features. It is almost impossible for a non-specialist to reason from these what "normal" or "typical" regolith looks like. Further, access to lunar material is highly restricted. And as publications rarely do not provide other than highly focused and narrowly tailored data, there is little potential for workers without personal access to sample to do any work with lunar material. To address both problems the authors have begun to make high resolution optical micrographs of entire thin sections of lunar regolith.

To date, there are two simulants for martian regolith: JSC Mars-1A, produced from palagonitic (weathered) basaltic tephra mined from the Pu'u Nene cinder cone in Hawaii [1] by commercial company Orbitec, and Mojave Mars Simulant (MMS), produced from Saddleback Basalt in the western Mojave desert by the Jet Propulsion Laboratory [2]. Until numerous recent orbiters, rovers, and landers were sent to Mars, weathered basalt was surmised to cover every inch of the martian landscape. All missions since Viking have disproven that the entire martian surface is weathered basalt. In fact, the outcrops, features, and surfaces that are significantly different from weathered basalt are too numerous to realistically count. There are gullies, evaporites, sand dunes, lake deposits, hydrothermal deposits, alluvium, etc. that indicate sedimentary and chemical processes. There is no one size fits all simulant. Each unique area requires its own simulant in order to test technologies and hardware, thereby reducing risk.

The key to any sustainable presence in space is the ability to manufacture necessary tools, parts, structures, spares, etc. in situ and on demand. Cost, volume, and up-mass constraints prohibit launching everything needed for long-duration or long-distance missions from Earth, including spare parts and replacement systems. There are many benefits to building items as-needed in situ using computer aided drafting (CAD) models and additive manufacturing technology: (1) Cost, up-mass, and volume savings for launch due to the ability to manufacture specific parts when needed. (2) CAD models can be generated on Earth and transmitted to the station or spacecraft, or they can be designed in situ for any task. Thus, multiple people in many locations can work on a single problem. (3) Items can be produced that will enhance the safety of crew and vehicles (e.g., latches or guards). (4) Items can be produced on-demand in a small amount of time (i.e., hours or days) compared to traditional manufacturing methods and, therefore, would not require the lengthy amount of time needed to machine the part from a solid block of material nor the wait time required if the part had to be launched from Earth. (5) Used and obsolete parts can be recycled into powder or wire feedstock for use in later manufacturing. (6) Ultimately, the ability to produce items as-needed will reduce mission risk, as one will have everything they need to fix a broken system or fashion a new part making it available on a more timely basis.

This slide presentation reviews the lunar resources that we know are available for human use while exploration of the moon. Some of the lunar resources that are available for use are minerals, sunlight, solar wind, water and water ice, rocks and regolith. The locations for some of the lunar resouces and temperatures are reviewed. The Lunar CRater Observation and Sensing Satellite (LCROSS) mission, and its findings are reviewed. There is also discussion about water retention in Permament Shadowed Regions of the Moon. There is also discussion about the Rock types on the lunar surface. There is also discussion of the lunar regolith, the type and the usages that we can have from it.

This document provides a formal, logical explanation of the parameters selected for the Figure of Merit algorithm used to evaluate lunar regolith simulant. The objectives, requirements, assumptions and analysis behind the parameters is provided. From NASA's objectives for lunar simulants a requirement is derived to verify and validate simulant performance versus lunar regolith. This requirement leads to a specification that comparative measurements be taken the same way on the regolith and the simulant. In turn this leads to a set of 9 criteria with which to evaluate comparative measurement. Many of the potential measurements of interest are not defensible under these criteria, for example many geotechnical properties of interest were not explicitly measured during Apollo and they can only be measured in situ on the Moon. A 2005 workshop identified 32 properties of major interest to users (Sibille Carpenter Schlagheck, and French, 2006). Virtually all of the properties are tightly constrained, though not predictable, if just four parameters are controlled. Three: composition, size and shape, are recognized as being definable at the particle level. The fourth, density, is a bulk property. In recent work a fifth parameter has been identified, which will need to be added to future releases of the Figure of Merit: spectroscopy.

Two troctolites from the lunar magnesium suite (Mg-suite), 76335 and 76535, have Sm-147-ND-143 and Rb-87- Sr-87 ages that do not indicate the same age for their respective sample. In the case of 76335, the Sm-147-ND-143 age is 4278 +/- 60 Ma, but the Rb-87-Sr-87 data does not reveal an isochron]. For 76535, the Sm-147-ND-143 age is significantly younger (4260 +/- 60 Ma) than the Rb-87- Sr-87 age (4570 +/- 70 Ma, Lambda = 1.402x10(exp -11)). This study was designed to discover why the Sm-147-ND-143 and Rb-87-Sr-87 ages did not match for each individual sample.

This section of the workshop describes the history of the moon, and offers explanations for the importance of understanding lunar history for engineers and users of lunar simulants. Included are summaries of the initial impact that is currently in favor as explaining the moon's formation, the crust generation, the creation of craters by impactors, the era of the lunar cataclysm, which some believe effected the evolution of life on earth, the nature of lunar impacts, crater morphology, which includes pictures of lunar craters that show the different types of craters, more recent events include effect of micrometeorites, solar wind, radiation and generation of agglutinates. Also included is a glossary of terms.