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Contour Crafting
Simulation plan for planetary infrastructure
buildup
Berok Khoshnevis, Anders Carlson, Neil Leach,
Madhu Thangavelu
University of Southern California
What is Contour Crafting?
A CC machine
Full-scale concrete structures
Strength of a 4-layer section
Supportless structures
House of
Brojerdi
Kashan
Vault structure implementation by CC
Lunar structures
Planetary applications
Basic infrastructure elements:
– Landing pad
– Blast protection wall
– Roads
– Shade walls
– Hangars
Other structures:
– Human habitat
– Green house
– Laboratories
– Fuel vessels
Malapert
Leibnitz
Large Lander - MALEO Site Office
Landing pad design
Landing pad, apron and blast wall
Road construction
Hangar construction
Sulfur Concrete
Infrastructure Design
Environmental Forces
• Lander thrust
• Micro-meteorites
• Thermal issues
– Low thermal conductivity
– Regional variation
– Sunlit vs. shaded
– Diurnal
• Dust
• Vacuum
• Moon gravity
• Radiation (solar protons & galactic cosmic rays)
ISRU Materials:
• Sulfur concrete
• Molten regolith
• Tensile reinforcement
Methods:
• Layered without formwork
Infrastructure Design
Materials and Methods
Boundary Conditions and Loadings:
• Lander thrust and fuel heat
• Solar energy
• Structure / regolith interface
Issues:
• Repeated heating / thrust
• Ejecta from fuel / dust
• Hard landing
• Micrometeorites
• Buckling / cracking
Infrastructure Design
Landing Pad and Apron
Boundary Conditions and Loadings:
• Rocket fuel heat and thrust
• Ejecta from exhaust / dust
• Structure / regolith interface
Issues:
• Nearby storage / facilities
• Distant settlement
• Shape
• Deterioration
Infrastructure Design
Blast Wall
DUST
FUEL
Boundary Conditions and Loadings:
• Solar energy
• Rovers
• Structure / regolith interface
Issues:
• Maximum payload
• Traction
• Buckling/cracking
Infrastructure Design
Roadways
Boundary Conditions and Loadings:
• Self weight
• Solar Energy
• Micrometeorites
• Structure / regolith
Issues:
• Thermal stress / strain
• Stability
• Crack propagation
• Radiation protection
Infrastructure Design
Hangar / Storage
SUN
SHADESHADE
Four dissimilar problems, one unified tool.
Abaqus / SIMULIA
• Implicit and explicit solvers
• Computational fluid dynamics
• Coupled Lagrangian-Eulerian analyses
• Heat transfer
• Shape optimization
• Shock, blast, contact, damaged plasticity, fracture, adaptive
remeshing, etc.
Infrastructure Design
Analysis & Design
Dual use – terrestrial applications
• Emergency shelters
• Construction in regions with limited water supply
• Autonomous shielding against radiation
Thank you
Questions?

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637118main khoshnevis presentation