Space Recycling and Manufacturing (REMADE-STUDY)

As we move to longer duration exploration missions and a sustained presence on the moon and/or mars, the incorporation of both In-Space Manufacturing (ISM) and in-space recycling in mission architectures will greatly enhance mission flexibility and reduce the need for resupply missions. In addition to providing the necessary resources to support and complement mission needs, the ability to recycle materials in space will reduce overall mission costs leading to an increased economic sustainability of exploration missions. To realize this benefit, both ISM and recycling must be developed in parallel as the two capabilities naturally complement each other. The utilization of recycled feedstocks for ISM greatly reduces the mass of feedstock that must be launched. In turn, the availability of ISM technologies increases the viability of recycling by providing a method to turn recycled feedstock into new necessary parts or structures manufactured in space and on non-terrestrial surfaces. The goal of this project is to consolidate prior learnings and multi-center knowledge to establish a data-informed foundation for the efficient material selection and end-of-material-life recycling efforts. This will be achieved through a trade study to determine which high value/impact materials that are already planned to be available as waste could be incorporated into the recycling and manufacturing processes to create new relevant parts or outfitting/construction feedstock. Polymers will be selected based on the likelihood of their availability as a waste material from ISS consumables data and the material properties needed for the recycling and in space manufacturing technologies included in the scope of this study. Specifically, appropriate polymers for both grinding/casting and filament production/FDM printing methods will be selected to ensure the versatility to manufacture different components. A regolith additive will be included as a combination to expand the amount of material that could be produced and target radiation shielding as a potential application.

Coupled in space manufacturing and recycling technologies are relevant to the ISS/LEO space stations, Gateway, the lunar surface, and longer space exploration missions such as those to Mars. As missions move further away from the Earth, the current logistics model to bring spares becomes less viable. In space manufacturing allows for the creation of spares and parts on-demand and in-space, as well as larger assembled structures that could not be launched in that configuration. Applications for recycled polymer feedstock processed into new parts or structures are wide-ranging. If replacement parts could be produced when needed, that would greatly reduce launch mass requirements. In addition, these processes could couple with outfitting objectives to create secondary structures, hand holds, brackets, shelving, basic furniture, and simple tools. Endless possibilities are enabled by simple flat sheets commonly seen walking down the lumber isle at a home improvement store combined with basic tools like a saw and a drill; a similar inventory may be facilitated by the recycling of polymers into sheet-stock. Finally, larger structures could be robotically assembled from recycled feedstock processed into numerous uniform building blocks. While the most benefit from developed ISM and recycling technologies applies to mid to late mission architectures, by starting technology development now it will be ready for infusion when needed. The ongoing formulation activities will allow for the incorporation of recyclability considerations into future mission planning.

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.