Nova Sirius

Sogamoso | Outfitting a Mars Habitat: A 3D Print Challenge

3D PRINTERS THE JOURNEY TO MARS STARTS HERE

High-Level Project Summary

3D printing has been one of the most efficient ways to solve some current issues problems in different fields of research; thanks to its versatility. Taking advantage of Mars’s environment and the features of the available printers, we propose tool kits for constructing novel solutions oriented to two primary purposes the power supply by wind using generators and blocks of concrete to build reconfigurable structures that provide comfortable, healthy, and customized habitats. Likewise, we present a contribution to redesigning the Rover wheel to have a plan B when these wheels have a fault; this solution considers a novel mechanism to prevent that dust or rocks from damaging the explorer.

Link to Final Project

https://sites.google.com/uptc.edu.co/nova-sirius/home

Link to Project "Demo"

https://youtu.be/W9uDLr6_70Q

Detailed Project Description

3D printing has been one of the most efficient ways some current issues problems in different fields of research and is even used in ever; thanks to its versatility, it can be used in areas such as entertainment, medicine, construction, exploration, transportation, clothing, tools, food, among others. Considering the characteristics of 3D printers, these on Mars would facilitate solving big problems thanks to their versatility for designing pieces of different materials and sizes. However, one of the challenges of printing on Mars is the small amount of available metal, the amount of energy that this process demands, and the printing range limited by the printers' size. Taking advantage of the Mars’ s environment and the features of the available printers, we propose tool kits for constructing novel solutions oriented to two primary purposes: i) the power supply by wind using generators based on the structure of a brushless motor, and ii) blocks of concrete to build reconfigurable structures that provide comfortable, healthy, and customized habitats. It is worth noting that, for this purpose, we involve in this solution the advantages of the metal printer that can use the copper available in the space shuttle, a plastic printer that can take advantage of the polymers known in the Mars environment; and a concrete printer, as these are currently used in the construction sector, that works with the materials found on the surface of Mars, which would allow astronauts to create different pieces. Likewise, we present a contribution redesigning the Rover wheel to have a plan B when these wheels have a fault; this solution considers a novel mechanism to prevent that dust or rocks from damaging the explorer. Other spare parts also can be constructed by using 3D printing, even new 3D printers. The suggested solutions focus mainly on designing mechanisms and units for habitat construction; the electronic devices demanded to assemble the proposed pieces must be provided by the mission until these can be produced locally.

1 Brushless Motor as Wind Generators

A brushless motor is a highly reliable, energy-saving, and maintenance-free motor that could be used even in flammable environment conditions. BLDC motors have the characteristic that they do not use brushes in the commutation for energy transfer; in this case, the switching is an electronic one. This property eliminates the major problem with conventional brushed electric motors, which produce friction, reduce performance, give off heat, are noisy, and require periodic replacement and, consequently, more maintenance. BLDC motors have many advantages over brushed DC motors and induction motors. Some of these advantages are:

- Better speed ratio

- Torque

- Greater dynamic response

- Greater efficiency

- Longer life

- Lower noise

- Increased speed range.

In addition, the motor torque-to-size ratio is much higher, which means that these motors can be used in applications where you work with reduced space. The brushless motor is made up of 3 fundamental pieces that are: i) the winding structure −the copper for winding can be extracted from the landing raft−, ii) the base that holds the motor (It has a plate shape that adjusts the wind turbine winding), and iii) the stator, It is where the neodymium magnets are going to go. These magnets will give the necessary magnetic field to give the selfinduction needed to generate voltage. Additionally, other metal pieces, such as the ball bearings, allow the stator's rotation. These bearings have an outer radius of 3 cm external and an inner radius of 1cm, which makes an axis of 1cm comprehensive. Depending on the revolutions of the brushless motor rotates, it will produce more or less voltage, and with different frequencies, so it is convenient to convert this energy, which is three-phase energy, into DC energy by using AC/DC converter and a regulator that controls the output level DC voltage. Astronauts can make bearings, stators, gears, and other pieces by using the metal printer that allows them to make larger pieces.

Table 1. Comparison between brushed motor and brushless motor

Considering the comparison shown in Table 1, the brushless motor is a great solution since it is extremely versatile for endless applications in different fields of action.

brushless motor 3D model

Brushless motor base

Brushless motor winding

brushless motor stator

2 Replacement for the Rover’s wheel

Besides the brushless motor, we propose a replacement for the Rover’s wheel. This replacement comprises three fundamental pieces:

a) the rim structure that will be attached to the chassis using screws by wrenches. The rim is designed by using metal printer, and the models of screws, nuts, wrench, and structures will made on the metal 3D printer.

b) The tire of the wheel will have a design that allows astronauts to see where the Rover is going to go. This tire will make by using a plastic 3D printer and it is comprised by eight pieces, which will assembled for assembled to form the entire tire. And finally.

c) there is a piece that covers the entire chassis (tire protection) structure so that rocks and sand do not enter the wheel, this piece is constructed by using the concrete printer.

the rim base

Tire from wheel of Rove

Front Ring for the chassis

Back Ring for the chassis

Rovert wheel

3 Concrete blocks as basic units for designing habitats

We also propose a design of concrete blocks inspired by Lego® bricks for building complex structures. These blocks can be done from scale structures, evaluating how the final construction would look, and allowing astronauts to configure a healthier, comfortable, and customized environment, which can be a crucial issue for the crew's motivation and motivation of Mars' habitants.

The biggests blocks be printed in concret impresors and the scale models be printed in plastic.

concrete block based in puzzle pieces.

large concrete block based in puzzle pieces.

The question now, is how could we make it work on Mars?

The main challenge is to build the suggested tools; for this, we have three printers of different printing materials, which allow astronauts to manufacture various pieces of several sizes; the dimensions of the printers considered for manufacturing are: Metal Printer: 150mm x 100mm x 100mm max volume with 0.1mm resolution. Plastic Printer: 310mm x 130mm x 140mm maximum volume with 0.1mm resolution. Concrete Printer: the concrete printer can make relatively large objects compared to the other two printers; maximum volume of 2m x 2m x 2m with 25mm resolution.

5 Goal

To design tool kits and blocks to construct different solutions that face the daily challenges of living on Mars, especially, these relates to the power supply and comfortable habitats, and other items needed for a one-year mission

6 Model descriptions

Next we describe many models that would allow astronauts to solve different problems

shelving - concret : This would allow astronauts to organize different elements, in order to be able to optimize the time when searching for a certain object .

bearing - metal: These bearing would allow astronauts to have a suitable piece for the brushless motor rotation

bristol - metal: These keys are essential for assembling and repairing equipment in the habitat.

Gears - metal or plastic: These gears are essential to be able to transmit the force between the axes

Keys - metal: This key is beneficial, since without it, equipment that has a fault could not be opened or repaired from 0.6cm to 1.9cm.

Dumbbells - concret: This is useful as part of a gym for the astronauts can exercise

Table - concret: this is a beneficial component for work productivity and comfort in a home on Mars. A table is a crucial piece for collaboration and teamwork promotion.

Linear Pinions- plastic or metal: These pinions are extremely useful to be able to have precision in the transmission of force.

Soup plate plastic definitely a utensil for the kitchen and daily life

Fork: definitely a utensil for the kitchen and daily life

nut10mm: These nuts are critical pieces for assembling different parts of the suggested tools

Space Agency Data

In order to provide a possible solution to the present challenge, we used the data provided by NASA on the conditions of Mars. For example, we studied relevant data for the rovers' proper functioning and parts that comprise them, along with the documentation and information related to the Sojourner, Spirit and Opportunity, Curiosity and Perseverance projects, which have been worked on Mars so far. Moreover, we also considered different hazards that have occurred while these projects have been in operation and other results of great relevance to the proper functioning of these projects. The data obtained from NASA provided valuable information on when possible risks could occur, why these appear, and the possible ideas that could be implemented to solve them.

This information was used to design many parts and components that would allow us to bring a quality of life on Mars as similar as possible to Earth. Using 3D printing, we propose building diverse elements usually found at home, such as tables, benches, bowls, and forks, among others. These elements are oriented to enable greater efficiency in the performance of daily activities, enhance the commissioned project execution, and improve the living conditions not only for the physical health of the astronauts but also for their psychological and emotional wellness. In our project, the relevance of mental health is something highly essential; wellness is a component that, although sometimes it is not valued as we would like or with enough importance, it must be taken into account and even more so on Mars, where it is possible to have isolated environment of loneliness and little interaction with relatives and friends (maybe, only in a remote way), which could affect the concentration to carry out commissioned projects or coexist appropriately with others.

Now, regarding the execution of project tasks, we consider that performing an orderly procedure when looking for a particular tool is something incredibly significant since this could determine the differentia between being able to solve or not a problem or emergency that arises unexpectedly, even more, when we have a large number of tools for different equipment or many pieces or spare parts in an operation; for this reason, we propose the printing of shelves and other stuff that allow astronauts to choose orderly the devices and tools, which will undoubtedly facilitate the performance of maintenance or repair tasks on Mars.

We also used data provided by the Human Research Program on its website, where there are available videos, podcasts, and other resources about the functioning of the environment on Mars. Likewise, we took into account the important factors in the transportation of astronauts and the factors that could affect their life on Mars for proposing solutions based on 3D printing that allow astronauts to face challenges of both health and daily life, allowing them to understand different issues of the adaption to a new environment and advance on knowledge about the universe (e.g., to comprehend the operations of the tools within the unknown environment, react variables that they have no control or find possible solutions to unexpected events). The Mars Exploration Program provides other data that we used through its web page about the details of Mars and its moons; all this information was helpful for creating models and designs based on the different conditions of Mars.

Additionally, we use data from the official documentation provided by the Nasa center on their website about the experiences of the projects executed so far; this web search allowed us to learn about how we can use previous experiences for finding or proposing problems solutions by using previous publications, and how we can take advantage of the recommendations on dealing with the difficulties that arise in space.

Hackathon Journey

How would you describe your experience with Space Apps? You learned? What inspired your team to choose this challenge? What was your approach to developing this project? How did your team resolve setbacks and challenges? Is there someone you would like to thank and why?

As university students we are aware that research is an area of great importance that allows the development of new technologies, the hackathon is a great opportunity for NASA to promote the development of skills of all students, from the smallest who contribute with their imagination and talent, and they inspire us to create a better tomorrow for them, even the greatest ones that drive us to continue advancing and to focus our efforts on new challenges. Being the first experience for all of us in an event like these, we feel the importance of continuing to develop and bring them to our environment, and above all it fills us with motivation to continue building knowledge from our homes. Since we were little we have heard about Mars and NASA research brings us closer step by step, and today they propose this magnificent challenge where we feel like inhabitants of the great red planet, it is to feel that yesterday's dream can be tomorrow's reality, and it has been our reality these two days.

To develop the project we focused on generating artifacts that would allow us to have a comfortable life, and the development of tools that will facilitate the generation of new ones to provide practical solutions to any new challenge or problem that may arise along the journey to Mars. Additionally, we focus on proposing a solution to generate energy that in the long term will allow us to have a colony. We would lie when we said that there were no problems, since the specifications of the challenge, while motivating our imagination, put limits on possible developments; however, a good distribution of tasks and collaboration between all team members when doubts arose, were a fundamental part of successfully completing this challenge. Finally, it is important to thank all of our family and friends who supported us and accompanied us on this journey... to Mars.