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In early 2024, NASA released a request for proposals addressing the construction of a permanent lunar base for the [https://www.nasa.gov/feature/artemis/ Artemis Mission]. [https://lawlor.cs.uaf.edu/~olawlor/ Dr. Orion Lawlor] led the creation of [https://docs.google.com/document/d/1W0xE08S_TUeKvRA961OPsiA_W6c5l_jKJNtGaGTW9B4/edit?usp=sharing the Aurora Robotics Team's proposal] in response to Appendix B of the [https://spacegrant.org/wp-content/uploads/2024/03/M2M-X-Hab-Challenge-Solicitation-2025.pdf NASA RFP document], sponsored by NASA Autonomous Robotic Construction Projects, including [https://ntrs.nasa.gov/citations/20220016161 Tall Lunar Tower (TLT)], [https://techport.nasa.gov/projects/116258 Precision Assembled Space Structures (PASS)], and [https://www.nasa.gov/centers-and-facilities/langley/automated-reconfigurable-mission-adaptive-digital-assembly-systems-armadas/ Automated Reconfigurable Mission Adaptive Digital Assembly Systems (ARMADAS)]. The proposal outlines the development of modular robotic tools for assembling regolith-covered hangar-like lunar habitats using pre-fabricated truss components. Throughout the course of the project, what the team delivered differed greatly from the original proposal.
<p>NASA's M2M X-Hab Academic Innovation Challenge for 2025 is a project led by the Aurora Robotics Lab at the University of Alaska Fairbanks, funded through NASA’s 2024–2025 Moon to Mars X-Hab Academic Innovation Challenge. The goal was to explore modular robotic construction techniques for lunar infrastructure, especially focusing on micrometeoroid-resistant arch structures assembled robotically from modular steel trusses.</p>
 
<p>The project culminated in the development of the Excahauler robotic platform with a custom-built arm and end-effector, capable of aligning and assembling scaled modular truss components. Despite limitations in time and resources, the team demonstrated key capabilities including truss manipulation, structural testing, and backfilling with regolith simulant.</p>


<h2>Project Vision and Mission</h2>
<h2>Project Vision and Mission</h2>
<ul>
<ul>
   <li><strong>Long-Term Vision:</strong> Transform the solar system using robotic construction with local materials.</li>
   <li><strong>Long-Term Vision:</strong> Transform the solar system using robotic construction with local materials.</li>
   <li><strong>Short-Term Vision:</strong> Robotic construction of Artemis Base Camp infrastructure.</li>
   <li><strong>Short-Term Vision:</strong> Develop robotic infrastructure construction technologies for the Artemis Base Camp.</li>
   <li><strong>Mission:</strong> Design and demonstrate robots capable of assembling large-scale lunar structures using modular steel trusses, simulating regolith backfilling with snow to represent radiation shielding.</li>
   <li><strong>Mission:</strong> Design and demonstrate robotic tools and modular structures capable of assembling scalable micrometeoroid-resistant lunar shelters.</li>
</ul>
</ul>
<h2>Key Structure: The L-Truss System</h2>
<p>The primary structural innovation was the development of the <strong>L-Truss</strong> — a modular trapezoidal truss segment. These trusses connect via push-fit endplates and spring-loaded capture pins to form straight or curved assemblies, including arches and retaining walls. The final design included:</p>
<ul>
  <li>Hybrid steel construction with 3D printed carbon-fiber polycarbonate alignment funnels.</li>
  <li>Spring-loaded pin latching mechanisms for tool-free robotic assembly.</li>
  <li>Optional upright members for regolith support and buckling resistance.</li>
  <li>Final tested form: 1.5m long, ~3kg, with a base angle of 22.5°.</li>
</ul>
<p>A scale 3D printable version is publicly available: [https://www.printables.com/model/1305834-trapezoidal-l-truss-clip-together-construction-mod L-Truss Model]</p>


<h2>Requirements</h2>
<h2>Requirements</h2>
<ul>
<ul>
   <li>The structure must allow a 2.6m x 2.6m vehicle to fit inside. (I.0)</li>
   <li>Accommodate 2.6m x 2.6m vehicles within the constructed arch structure. (I.0)</li>
   <li>Structural elements must not exceed 2.0 meters for ease of transport. (I.1.1)</li>
   <li>Truss segments must remain under 2.0 meters for transport and robotic handling. (I.1.1)</li>
   <li>The structure must support a regolith simulant (snow) coating of at least 0.2m thickness to simulate radiation and thermal protection. (O.0)</li>
   <li>Regolith shielding: Support ≥0.2m regolith equivalent for radiation/thermal protection. (O.0)</li>
   <li>The structure must tolerate a compressive load of 300 kgf and demonstrate a safety factor of at least 2. (I.1.2, I.2.1)</li>
   <li>Minimum compressive load capacity of 300 kgf with ≥2.0 safety factor. (I.1.2, I.2.1)</li>
   <li>Assembly must be robotically achievable, with all tools having a path to robotic automation. (E.0, E.2)</li>
   <li>Robot-compatible assembly path: all actions must have potential for automation. (E.0, E.2)</li>
</ul>
</ul>


<h2>Concept of Operations</h2>
<h2>Concept of Operations</h2>
<p>The project centers on the Excahauler robot, a tracked platform that supports remote and semi-autonomous tool operation. It performs:</p>
<h3>Lunar Deployment Plan</h3>
<ul>
<ol>
   <li>Transport of modular truss components using a forklift-like attachment.</li>
   <li><strong>Site Preparation:</strong> The Excahauler prepares a foundation using excavation tools.</li>
   <li>Teleoperated and semi-autonomous connection of truss elements via 3D-printed prototypes and full-scale demonstration hardware.</li>
   <li><strong>Truss Deployment:</strong> Trusses are unloaded from a logistics lander and staged for assembly.</li>
   <li>Demonstration of alignment and pin-connection mechanisms using camera feedback and manipulator tools.</li>
   <li><strong>Structural Assembly:</strong> Robots align and push-connect trusses into arches or walls.</li>
   <li>Backfilling simulation with snow representing lunar regolith.</li>
   <li><strong>Backfilling:</strong> Simulated regolith (e.g. snow or basalt dust) is applied over the structure.</li>
</ul>
  <li><strong>Use Phase:</strong> Covered arches serve as shielding for sensitive lunar equipment or crew.</li>
</ol>


<h2>Key Project Goals</h2>
<h3>Ground Demonstration Activities</h3>
<ul>
<ul>
   <li><strong>Radiation Protection:</strong> Simulate protection using snow as a regolith analog.</li>
   <li>1:10 scale arch model tested with regolith simulant (basalt dust).</li>
   <li><strong>Thermal Insulation:</strong> Demonstrate covered structures that insulate against lunar temperature swings.</li>
   <li>Full-scale hybrid trusses fabricated and manipulated via teleoperation.</li>
   <li><strong>MMOD Protection:</strong> Cover completed structure to simulate defense against micrometeoroids.</li>
   <li>Robotic assembly verified using Excahauler and custom-built 2500:1 reducer gearbox arm.</li>
  <li><strong>Scalability:</strong> Test modular, repeatable construction approaches suitable for larger lunar operations.</li>
</ul>
</ul>


<h2>Project Phases</h2>
<h2>Project Phases</h2>
<ol>
<ol>
   <li><strong>Preliminary Design Review (PDR):</strong> November 15, 2024 ([https://spacegrant.org/xhab/ M2M X-Hab Schedule])</li>
  <li><strong>System Definition Review (SDR):</strong> October 4, 2024</li>
   <li><strong>Critical Design Review (CDR):</strong> January 17, 2025</li>
   <li><strong>Preliminary Design Review (PDR):</strong> November 15, 2024</li>
   <li><strong>Progress Checkpoint:</strong> March 7, 2025</li>
   <li><strong>Critical Design Review (CDR):</strong> January 24, 2025</li>
   <li><strong>Final Demonstration and Report:</strong> May 30, 2025</li>
   <li><strong>Progress Checkpoint Review (PCR):</strong> April 18, 2025</li>
   <li><strong>Final Demonstration & Report:</strong> May 30, 2025</li>
</ol>
</ol>


<h2>Baseline Design Solution</h2>
<h2>Robot System: Excahauler</h2>
<ul>
  <li>Originally designed for the 2022 NASA Break the Ice Challenge.</li>
  <li>Outfitted with a custom modular manipulator arm with 3D printed stepped planetary gearboxes.</li>
  <li>Used in successful teleoperated tests to transport and align L-Truss segments.</li>
</ul>
 
<h2>Software and Simulation</h2>
<p>The team developed and tested robotic workflows using the following tools:</p>
<ul>
<ul>
   <li><strong>Structure:</strong> Modular trapezoidal truss segments connected via pin-based mechanisms, enabling 0° or 22.5° angles.</li>
   <li><strong>Godot-based simulator:</strong> Visualized structure assembly and layout.</li>
  <li><strong>Materials:</strong> Full-scale steel for load-bearing demonstrations; 3D-printed ABS for scaled testing.</li>
   <li><strong>Custom autonomy stack (LUNATIC):</strong> Handles teleoperation, control, and vision.</li>
   <li><strong>Robot:</strong> Excahauler robot platform for transport, manipulation, and teleoperated assembly.</li>
   <li><strong>ROS2 / MoveIt:</strong> Inverse kinematics modeled, pending full integration for automation.</li>
   <li><strong>Performance:</strong> FEM simulations confirm load-bearing capabilities and safety factor >2.</li>
</ul>
</ul>


<h2>Verification and Testing</h2>
<h2>Testing and Validation</h2>
<ul>
<ul>
   <li>Destructive and nondestructive testing of 3D-printed and steel components.</li>
   <li>FEM analysis showed safety factor >2.6 under 500N compressive loads.</li>
   <li>Full-scale assembly and backfill simulation using snow in Fairbanks winter conditions.</li>
   <li>Hybrid trusses withstood >500N axial loads; failure occurred at 230N in bending.</li>
   <li>Teleoperation tests for precision alignment and assembly with tracked mobility.</li>
   <li>1/10 scale arch supported >12kg in Earth gravity, equivalent to 36+ tonnes in Mars gravity at full scale.</li>
</ul>
</ul>


<h2>Educational Integration</h2>
<h2>Educational Integration</h2>
<p>The project integrates into UAF's systems engineering courses, involving both undergraduate and graduate students in design, simulation, fabrication, testing, and outreach activities.</p>
<p>Project integrated into UAF's CS 493 (Fall) and CS 454 (Spring), providing hands-on systems engineering experience to undergraduates and graduate students in mechanical and computer science disciplines.</p>
 
<h2>Outreach Activities</h2>
<ul>
  <li><strong>Party in the Park:</strong> Public engagement event with live robot demos.</li>
  <li><strong>FTC Robotics Tours:</strong> Guided tour for K–12 robotics students.</li>
  <li><strong>UAF Engineering Open House:</strong> Structural demo and recruiting opportunity.</li>
</ul>
 
<h2>Lessons Learned</h2>
<ul>
  <li><strong>Structure:</strong> Even small teams benefit from defined leadership and task ownership.</li>
  <li><strong>Planning:</strong> Conservative scoping ensures project deliverables can be met.</li>
  <li><strong>Fabrication:</strong> Early design-for-manufacturing saves time and enables iteration.</li>
</ul>
 
<h2>Future Work</h2>
<ul>
  <li>Complete full-scale robotic arch assembly.</li>
  <li>Fully integrate MoveIt into robotic control stack for autonomous alignment.</li>
  <li>Refine end-effector precision and truss fabrication for large-scale repeatability.</li>
</ul>


<h2>Additional Information</h2>
<h2>Additional Information</h2>
<p>For more details, please contact Dr. Orion Lawlor at oslawlor@alaska.edu or visit the [https://spacegrant.org/xhab/ NASA X-Hab Challenge website].</p>
<p>Project Lead: Andrew Mattson, UAF CS BS/MS student 
Faculty Advisor: Dr. Orion Lawlor (oslawlor@alaska.edu)</p>
<p>More at: [http://auroraroboticslab.com auroraroboticslab.com]</p>

Revision as of 12:08, 27 June 2025

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Overview

NASA X-Hab Logo

NASA's M2M X-Hab Academic Innovation Challenge for 2025 is a project led by the Aurora Robotics Lab at the University of Alaska Fairbanks, funded through NASA’s 2024–2025 Moon to Mars X-Hab Academic Innovation Challenge. The goal was to explore modular robotic construction techniques for lunar infrastructure, especially focusing on micrometeoroid-resistant arch structures assembled robotically from modular steel trusses.

The project culminated in the development of the Excahauler robotic platform with a custom-built arm and end-effector, capable of aligning and assembling scaled modular truss components. Despite limitations in time and resources, the team demonstrated key capabilities including truss manipulation, structural testing, and backfilling with regolith simulant.

Project Vision and Mission

  • Long-Term Vision: Transform the solar system using robotic construction with local materials.
  • Short-Term Vision: Develop robotic infrastructure construction technologies for the Artemis Base Camp.
  • Mission: Design and demonstrate robotic tools and modular structures capable of assembling scalable micrometeoroid-resistant lunar shelters.

Key Structure: The L-Truss System

The primary structural innovation was the development of the L-Truss — a modular trapezoidal truss segment. These trusses connect via push-fit endplates and spring-loaded capture pins to form straight or curved assemblies, including arches and retaining walls. The final design included:

  • Hybrid steel construction with 3D printed carbon-fiber polycarbonate alignment funnels.
  • Spring-loaded pin latching mechanisms for tool-free robotic assembly.
  • Optional upright members for regolith support and buckling resistance.
  • Final tested form: 1.5m long, ~3kg, with a base angle of 22.5°.

A scale 3D printable version is publicly available: L-Truss Model

Requirements

  • Accommodate 2.6m x 2.6m vehicles within the constructed arch structure. (I.0)
  • Truss segments must remain under 2.0 meters for transport and robotic handling. (I.1.1)
  • Regolith shielding: Support ≥0.2m regolith equivalent for radiation/thermal protection. (O.0)
  • Minimum compressive load capacity of 300 kgf with ≥2.0 safety factor. (I.1.2, I.2.1)
  • Robot-compatible assembly path: all actions must have potential for automation. (E.0, E.2)

Concept of Operations

Lunar Deployment Plan

  1. Site Preparation: The Excahauler prepares a foundation using excavation tools.
  2. Truss Deployment: Trusses are unloaded from a logistics lander and staged for assembly.
  3. Structural Assembly: Robots align and push-connect trusses into arches or walls.
  4. Backfilling: Simulated regolith (e.g. snow or basalt dust) is applied over the structure.
  5. Use Phase: Covered arches serve as shielding for sensitive lunar equipment or crew.

Ground Demonstration Activities

  • 1:10 scale arch model tested with regolith simulant (basalt dust).
  • Full-scale hybrid trusses fabricated and manipulated via teleoperation.
  • Robotic assembly verified using Excahauler and custom-built 2500:1 reducer gearbox arm.

Project Phases

  1. System Definition Review (SDR): October 4, 2024
  2. Preliminary Design Review (PDR): November 15, 2024
  3. Critical Design Review (CDR): January 24, 2025
  4. Progress Checkpoint Review (PCR): April 18, 2025
  5. Final Demonstration & Report: May 30, 2025

Robot System: Excahauler

  • Originally designed for the 2022 NASA Break the Ice Challenge.
  • Outfitted with a custom modular manipulator arm with 3D printed stepped planetary gearboxes.
  • Used in successful teleoperated tests to transport and align L-Truss segments.

Software and Simulation

The team developed and tested robotic workflows using the following tools:

  • Godot-based simulator: Visualized structure assembly and layout.
  • Custom autonomy stack (LUNATIC): Handles teleoperation, control, and vision.
  • ROS2 / MoveIt: Inverse kinematics modeled, pending full integration for automation.

Testing and Validation

  • FEM analysis showed safety factor >2.6 under 500N compressive loads.
  • Hybrid trusses withstood >500N axial loads; failure occurred at 230N in bending.
  • 1/10 scale arch supported >12kg in Earth gravity, equivalent to 36+ tonnes in Mars gravity at full scale.

Educational Integration

Project integrated into UAF's CS 493 (Fall) and CS 454 (Spring), providing hands-on systems engineering experience to undergraduates and graduate students in mechanical and computer science disciplines.

Outreach Activities

  • Party in the Park: Public engagement event with live robot demos.
  • FTC Robotics Tours: Guided tour for K–12 robotics students.
  • UAF Engineering Open House: Structural demo and recruiting opportunity.

Lessons Learned

  • Structure: Even small teams benefit from defined leadership and task ownership.
  • Planning: Conservative scoping ensures project deliverables can be met.
  • Fabrication: Early design-for-manufacturing saves time and enables iteration.

Future Work

  • Complete full-scale robotic arch assembly.
  • Fully integrate MoveIt into robotic control stack for autonomous alignment.
  • Refine end-effector precision and truss fabrication for large-scale repeatability.

Additional Information

Project Lead: Andrew Mattson, UAF CS BS/MS student Faculty Advisor: Dr. Orion Lawlor (oslawlor@alaska.edu)

More at: auroraroboticslab.com

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