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“ Manufacturing Systems of the Mars Homestead Project ” Local Steel, Aluminum, and Glass

“ Manufacturing Systems of the Mars Homestead Project ” Local Steel, Aluminum, and Glass. Damon Ellender MHP Programming Team DamonE@marshome.org. Manufacturing. Local Manufacturing is key to long-term planetary settlement. Requirements. Steel Processing 400kg/day 1500K

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“ Manufacturing Systems of the Mars Homestead Project ” Local Steel, Aluminum, and Glass

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  1. “Manufacturing Systems of the Mars Homestead Project”Local Steel, Aluminum, and Glass Damon Ellender MHP Programming Team DamonE@marshome.org

  2. Manufacturing • Local Manufacturing is key to long-term planetary settlement

  3. Requirements • Steel Processing 400kg/day 1500K • Aluminum Processing 25kg/day 1000K • Glass Processing 200kg/day 1200K-1400K • Manufactured Products as needed for construction(i.e. Structural, wire,…) • Dual use or Flexible equipment used where possible

  4. Glass Process • Floated on Tin, Pilkington Process, 2mx4m float tray, made from local brick, covered to protect from dust • Cooled using CO2 in Lehr, 2mx2m, made from local brick. Rollers imported. • Cut into 1m x 1mx5mm glass panels for transport and further cutting. • Located Outdoors

  5. LCC Steel Process • Low Carbon Content (LCC) Steel is better for low temperature application • All products made of 6mm Sheet or cast directly • Provision for Rolling ‘Strip’ depending on size of Steel Batch • Located Outdoors

  6. Strip Caster • 6mm thick x2m wide • Can be outdoors though dust may require enclosed(not pressurized) areas • Pickling could also be done in enclosed area to ensure recovery of acids/caustics.

  7. Typical Strip Casting Process • All products made of 6mm Sheet or cast directly • Provision for Rolling ‘Strip’ depending on size of Steel Batch

  8. Reference Earth Installations

  9. Slab Caster • For Context • Not practical for amount of steel manufactured unless larger sections needed(i.e. rails) • Batch Casting or Direct Chill better alternative

  10. Aluminum Process • Strip Casting possible using same process as Steel • Direct Chill is also possible for Aluminum, not sure for Steel.

  11. Aluminum Direct Chill Casting • Ingots Poured Vertically • Continuous Quench with Water or CO2 • Once Mold is full, valve shuts, and ingot is rotated and pressed out by ram. • Other material could use this process(i.e steel)

  12. Annealing Furnace • Located Outdoors • Capable of 1000K Temperatures • Capable of Controlled Cooling(using CO2) • Approximately 5mx1mx1m made from local Refractory • Heat Exchanger Imported(1m3, 100kg) • Uses Steam from Nuclear Reactor for Controlled Heating

  13. Material Transport • Need Glass, Steel, and Al transported from Refining to Manufacturing Airlock • Need Steel Rolls transported to Annealing Oven • Need Finished Products transported from Manufacturing Airlock to Area of Use • Rover or Automated Robot Carrier could easily be programmed to perform this function.

  14. Products Processing (Indoors) • Sheet Metal • Foil Foil Mill (8m2,1000kg) • Ducting 4m brake(4m2, 200kg), Resistance Welder(.25m2,50kg), Rivets • Piping/Tubing Tube Mill(4m2,500kg) • Wire/Cable Stripper(4m2,200kg), Wire Mill(6m2, 500kg) • Mesh Expander(3m2,200kg) • Stamped • Housings Press and Dies(4m2, 200kg), Castings(.5m2, 50kg) • Structural Members Press and Dies(4m2,200kg), Castings(4m2,100kg) • Rover Wheels Castings(.5m2,50kg), Press and Dies(4m2, 200kg) • Roll Winder/Unwinder (4m2, 400kg) • Cast Metal • Structural Beams Direct Chilled, Castings(4m2, 100kg) • Castings Castings(1m2, 100kg) • Valves • Sprinklers • Rover Parts • Glass Glass Cutter(2mx1m, 100kg) • Coatings • Zinc Galvanizing Use Locally Made PE Tank, and Zinc • Powder Coating Line Includes Oven, 3mx3m, 400kg • Electroplating Use Locally Made PE Tank, and appropriate Eplating solution • Shop • One Off Manufacture Drill Press, CNC Lathe, CNC Milling Machine (H&V), Grinders, Cutters • Prototyping Rapid Prototyping System, Wax or Plastic Investments Minimum • Robots/Automation • 6 DOF Motoman Handles Resistance Welder, Plasma Cutter, and Manipulator • Crane Loading and Unloading of Heavy Items

  15. Import Listing

  16. Slitter • May be used for making wire ribbon as well.

  17. Cutting device • Diamond Saw • Cuts both steel and glass

  18. Tubing Mill-Formers • Rolls strips into a tube and welds. • Tubing out can be rolled or cut in lengths.

  19. Coiler/DeCoiler • Roll and Unrolls Tubing, Strip, Wire, and Cable. • 200kgs per unit • ~1mx2m floorspace

  20. Steel Mill Control Room • For Context • Supervision of Process • Video • Instruments • Visual • Programming of new process

  21. Powder Coat Oven • Finished Products • Durable Epoxy Coating • Can be used on Steel and Aluminum

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