Forging the Future Lunar Settlement with In-Situ Aluminum Extraction

This NSTGRO25 proposal builds upon the Lunar In-Situ Aluminum Production through Molten Salt Electrolysis (LISAP-MSE) process which was initially developed for the NASA BIG Idea Challenge 2023 (Lunar Forge theme). This approach seeks to electrolytically reduce aluminum oxide into metallic aluminum using molten salt electrolysis (MSE) with calcium chloride as the electrolyte. The process offers a viable path to lunar aluminum production, eliminating the need to transport large amounts of consumables from Earth. The development of the LISAP-MSE process will contribute to NASA's goal of enabling long-term human habitation on the Moon by providing the means to manufacture essential components locally. In addition to lunar operations, the technology could also be adapted for in-space manufacturing and asteroid mining, extending its relevance beyond the Moon. To address the challenges associated with the harsh lunar environment, this project seeks to develop a complete reactor system intended for the lunar surface, building upon lessons learned from initial experiments on Earth. Thus, the research plan is structured around three key objectives: 1) Electrode Material Selection: Identify non-graphitic materials that resist corrosion and maintain conductivity in molten salts at high temperatures; 2) Optimization of Process Parameters: Experiment with different cell voltages, currents, and operating temperatures to maximize aluminum yield and system efficiency; and 3) Reactor Development: Build and test a fully enclosed electrolysis reactor capable of continuous operation under controlled conditions, such as inert gas environments, to simulate lunar conditions.

This is a mature technology (TRL 7+) — the realistic path in is usually NASA's Technology Transfer Program: licensing an existing NASA patent, or a Space Act Agreement to use NASA facilities/expertise directly. NASA also runs a startup licensing program with no upfront fee for companies formed to commercialize a specific NASA technology.

None of these are guaranteed paths for this specific project — TechPort itself doesn't have an "apply" button. Reaching out to the contact(s) above with a specific question is usually the fastest way to find out what's actually open.