Recycling of aluminum for a multi-tool in a Lunar or Martian settlement

Paper number

IAC-24,A3,IP,200,x87344

Author

Mr. Matvei Andreev, Germany

Coauthor

Mr. Manuel Ortega, Technical University of Berlin, Germany

Coauthor

Mr. Francesco Caltavituro, OHB System AG-Bremen, Germany

Coauthor

Dr. Marco Berg, OHB System, Germany

Coauthor

Dr. Barbara Imhof, LIQUIFER Systems Group, Austria

Coauthor

Mr. René Waclavicek, LIQUIFER, Austria

Coauthor

Dr. Daniel Schubert, Deutsches Zentrum für Luft- und Raumfahrt e.V. (DLR), Germany

Coauthor

Dr. Advenit Makaya, European Space Agency (ESA), The Netherlands

Coauthor

Mr. Marco Blanco, European Space Agency (ESA), The Netherlands

Coauthor

Mr. Frank Koch, Germany

Year

2024

Abstract

\noindent Sustainable, long-term human presence in space is currently limited by the high mission dependency from 
Earth, which includes the delivery of tools, spare parts, and other supply materials. Conversely, new recycling
and re-use capabilities allow further exploration that would otherwise be prohibitive in terms of volume, mass,
and costs. The ESA-founded project HARMONISE led by OHB System AG as Prime Contractor with Liquifer 
Space Systems Group, and Azimut Space as sub-contractors touches upon in-situ recycling and re-using of
available resources in a future Lunar or Martian habitat.\\ \\
The project investigated recycling of polyethylene packaging into a filament for fused filament fabrication 
applications, re-melting and casting of scrap aluminium to produce tools, and finally partial as well as complete
re-utilisation of rack blind panels and cargo transfer bags dividers for furniture elements fabrication conceived 
for future habitat. The project aligns with ESA space debris mitigation policy towards environmentally 
sustainable space activities.
Azimut Space GmbH has investigated the manufacturing of a multi-tool metal casting demonstrator, the 
materials, equipment, and methods used in the manufacturing process, as well as the testing and verification of 
the tool. \\ \\
During this study, sand casting was used to recycle aluminum components and create a multi-tool that can
assist astronauts in the construction and maintenance of the habitat, such as by fastening bolts and nuts. The 
design of the tool was affected by additional factors given the challenging Lunar environment, the demand for
minimization of post-processing efforts, as well as ergonomic requirements. This manuscript provides key 
insights gained during the metal recycling demonstrator, including technical challenges posed by the innovative
combination of requirements, aspects related to manufacturing, as well as the outcomes of the test campaign 
and verification that lead to the next iteration of the multi-tool design.\\ \\
{\bf Keywords:} Moon, recycling, aluminum, casting, tools

Abstract document

IAC-24,A3,IP,200,x87344.brief.pdf

Manuscript document

(absent)