tAMing particles

https://drive.google.com/drive/folders/1O9TjtHH1jcKr0F1WGvIDV9PzVdt0b_4f

https://www.canva.com/design/DAFN3pi-1Uk/aM4zcw1Ft4v44qFFUq7afw/view?utm_content=DAFN3pi-1Uk&utm_campaign=designshare&utm_medium=link&utm_source=publishsharelink

Although NASA’s research on Deep Space Habitability identifies hardwired workstation, waste removal and recycling system, viewing window and private crew quarters as capabilities essential or significantly enhancing the missions, the rough landing complicates this challenge. Thus, tooling and replacement parts such as rover wheel become equally essential for the year long mission.

Our approach provides the database type structure of the building blocks that can be used for multiple purposes. By combining a limited number of parts many different assemblies can be created. To illustrate the approach, we have developed models of some tools. For example, by having an interchangeable handle and a screwdriver holder, tools such as screw drivers, knives, hand cranked drills can be assembled. Illustrations of these hierarchies are presented in the slides and further discussed on project documentation that can be found under the "Link to Final Project".

The models can be further developed, and topology optimized. We approached this using Rhino Grasshopper software, which allows to do parametric modeling and design. We have decided to create a proof of concept tool, that would allow to divide any given solid body into cells and apply multipipe at the boundaries.

This tool would allow to have quick and easy mass or geometry optimization. Most of the parts would be easily printable without the supports. With additional optimization, this can be done as a default tool feature. This is especially helpful while saving mass with general elements like bricks, handle and various other elements that would require higher volume, but does not require especially and relatively high stiffness. 

In addition, we have developed a printable rover wheel. The full-scale rover wheel was considered - 20.7” in diameter. To fit on a printer bed, we are making the wheel of the several parts and printing on both printers, metal and plastic. That also helps to save precious metal. The wheel consists of four metal hub parts that are assembles with printed screws made for the purpose. The outer wheel or the “tire” is also made of four metal rings segmented into 12 segments to fit on a printer bed. While the middle of the wheel is made of plastic honeycomb pattern sections, that interlock together. To check the feasibility of using plastic for the rover wheel in our design, we ran a quick static simulation, that gave us a safety factor of 1.3 for Earth conditions taking the conservative plastic yield strength of 13.5MPa. While on Mars we are getting the safety factor of 3.75 due to the lower gravitation. 

The mars rover wheel is designed with the idea of a 3D printable wheel which is build out of segments. The design approach was to make something that would be interchangeable, easily replaceable and would still overcome the loads from the rover. You can say that the wheel is made out three „Pizzas“ and one „Wheel pizza“ is made of of 12 Pizza slice formed segments and the middle shaft hub. The Pizza sliced segments are made from two parts, which are made from two materials, utilizing the metal printer for it‘s strength and plastic for it‘s lightness and bigger printer zones. The pizza slices will inter-connect with each other through the honeycomb structure pattern. They would fit into each other and hold together due to the mars rover weight loads. This is better illustrated in the supporting challenge documentation.

The most important Space Agency resource that we have used in our project was NASA’s report on Deep Space Habitability Design Guidelines Based on the NASA NextSTEP Phase 2 Ground Test Program. That report has provided the clear guidelines on what are the essential capabilities in a deep space habitat and helped us to better understand how to tackle the chosen challenge. This let us define areas for which interchangeable printable parts would be necessary. In addition, we have reviewed the NASA 3D models database to see what tools are already available. Moreover, we have reviewed NASA’s Analog Missions to get a picture of how missions are simulated here on Earth.

We are a team of 3D printing enthusiasts and hobbyist working in a space industry designing Cube satellites. 3D printing challenge in outfitting Mars habitat among the other challenges seemed a natural choice considering our passion for space exploration and 3D printing.

We have approached the challenge by considering the wide scope of Mars habitat capabilities and listing the items that can be used to achieve the essential purposes. We when compiled a list of assemblies that use the interchangeable printable parts. However, realizing that we have taken too wide scope, we then slightly pivoted and narrowed the scope down to the challenge specific items. We then chose to design tools that were lost during landing and the rover wheel that was also damaged during landing. We came up with a number of designs that are presented in slides and further described in detailed project description

We have learned that in a very limited time it is wiser to detail the ideas early leaving some out of the scope.

Overall, we had good time tackling NASA challenge and are happy about our developments.

All 3D models were created by the team.

NASA/TP-2020-220505 - Deep Space Habitability Design Guidelines Based on the NASA NextSTEP Phase 2 Ground Test Program [November 2019] was used as a reference to define important habitat capabilities

https://patents.google.com/patent/US5644959A/en was used as a reference and inspiration designing universal socket head.

#mars #3Dprinting #tools #lifeonmars #topologyoptimisiation #SlavaUkraini