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Manufacturing Systems of the Mars Homestead Project Local Steel, Aluminum, and Glass Damon Ellender MHP Programming Team

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Presentation on theme: "Manufacturing Systems of the Mars Homestead Project Local Steel, Aluminum, and Glass Damon Ellender MHP Programming Team"— Presentation transcript:

1 Manufacturing Systems of the Mars Homestead Project Local Steel, Aluminum, and Glass Damon Ellender MHP Programming Team

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 –FoilFoil Mill (8m2,1000kg) –Ducting4m brake(4m2, 200kg), Resistance Welder(.25m2,50kg), Rivets –Piping/TubingTube Mill(4m2,500kg) –Wire/CableStripper(4m2,200kg), Wire Mill(6m2, 500kg) –MeshExpander(3m2,200kg) –Stamped HousingsPress and Dies(4m2, 200kg), Castings(.5m2, 50kg) Structural MembersPress and Dies(4m2,200kg), Castings(4m2,100kg) Rover WheelsCastings(.5m2,50kg), Press and Dies(4m2, 200kg) –Roll Winder/Unwinder(4m2, 400kg) Cast Metal –Structural BeamsDirect Chilled, Castings(4m2, 100kg) –CastingsCastings(1m2, 100kg) Valves Sprinklers Rover Parts GlassGlass Cutter(2mx1m, 100kg) Coatings –Zinc GalvanizingUse Locally Made PE Tank, and Zinc –Powder Coating LineIncludes Oven, 3mx3m, 400kg –ElectroplatingUse Locally Made PE Tank, and appropriate Eplating solution Shop –One Off ManufactureDrill Press, CNC Lathe, CNC Milling Machine (H&V), Grinders, Cutters –PrototypingRapid Prototyping System, Wax or Plastic Investments Minimum Robots/Automation –6 DOF MotomanHandles Resistance Welder, Plasma Cutter, and Manipulator –CraneLoading and Unloading of Heavy Items

15 Import Listing EquipmentFloorspace AreaVolumeWeight Foil Mill4mx2m8m m Brake4mx1m4m3200 Resistance Welder.5mx.5m.125m350 Tube Mill2mx2m4m3400 Stripper2mx2m4m3200 Wire Mill3mx2m6m3500 Mesh Expander3mx1m3m3100 Press and Dies4mx1m4m3200 Castings4mx1m5m3250 Glass Cutter2mx1m2m3100 Powder Coat Line3mx3m9m3400 Galvanizing Tank6mx1m6m3Locally Made Electroplating Tank6mx1m6m3Locally Made CNC Lathe Mill Drill5mx2m20m31500 Laser or Water Cutter6mx2m12m3500 Plasma Arc Cutter.5mx.5m.125m350kg Rapid Prototyping Machine1mx1m2m3100kg 6DOF Robot1mx1m2m3250kg Crane3m radius3m3200kg Heat Exchangers Annealing Furnace 5mx2m1m3100kg Valving for CO2 Cooling.5mx.5m.25m3200kg Rollers(50mmRx3m)3mx6m3m3500kg

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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