Lunar Contour Crafting: A Novel Technique for ISRU-Based Habitat Development

As the nation prepares to return to the Moon, it is apparent that the viability of long duration visits with appropriate radiation shielding/crew protection, hinges on the development of Lunar structures, preferably in advance of a manned landing, and preferably utilizing in-situ resources. Contour Crafting is a USC-patented technique for automated development of terrestrial concrete-based structures. The process is relatively fast, completely automated, and supports the incorporation of various infrastructure elements such as plumbing and electrical wiring. This paper will present a conceptual design of a Lunar Contour Crafting system designed to autonomously fabricate integrated structures on the Lunar surface using high-strength concrete based on Lunar regolith, including glass reinforcement rods or fibers fabricated from melted regolith. Design concepts will be presented, as well as results of initial tests aimed at concrete and glass production using Lunar regolith simulant. Key issues and concerns will be presented, along with design concepts for an LCC testbed to be developed at MSFC's Prototype Development Laboratory (PDL).