NASA X-Hab 2025: Modular Robotic Construction

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Overview

NASA X-Hab Logo

In early 2024, NASA released a request for proposals addressing the construction of a permanent lunar base. Dr. Orion Lawlor led the Aurora Robotics Team's proposal in response to Appendix B of the NASA RFP document, sponsored by NASA's Autonomous Robotic Construction Projects - TLT, PASS, ARMADAS. The proposal outlines the development of modular robotic tools for assembling regolith-covered hangar-like lunar habitats using pre-fabricated truss components.

Project Vision and Mission

• Long-Term Vision: Transform the solar system using robotic construction with local materials.
• Short-Term Vision: Robotic construction of Artemis Base Camp infrastructure.
• Mission: Design and demonstrate robots capable of assembling large-scale lunar structures using modular steel trusses, simulating regolith backfilling with snow to represent radiation shielding.

Requirements

• The structure must allow a 2.6m x 2.6m vehicle to fit inside. (I.0)
• Structural elements must not exceed 2.0 meters for ease of transport. (I.1.1)
• The structure must support a regolith simulant (snow) coating of at least 0.2m thickness to simulate radiation and thermal protection. (O.0)
• 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)
• Assembly must be robotically achievable, with all tools having a path to robotic automation. (E.0, E.2)

Concept of Operations

The project centers on the Excahauler robot, a tracked platform that supports remote and semi-autonomous tool operation. It performs:

• Transport of modular truss components using a forklift-like attachment.
• Teleoperated and semi-autonomous connection of truss elements via 3D-printed prototypes and full-scale demonstration hardware.
• Demonstration of alignment and pin-connection mechanisms using camera feedback and manipulator tools.
• Backfilling simulation with snow representing lunar regolith.

Key Project Goals

• Radiation Protection: Simulate protection using snow as a regolith analog.
• Thermal Insulation: Demonstrate covered structures that insulate against lunar temperature swings.
• MMOD Protection: Cover completed structure to simulate defense against micrometeoroids.
• Scalability: Test modular, repeatable construction approaches suitable for larger lunar operations.

Project Phases

1. Preliminary Design Review (PDR): November 15, 2024 (M2M X-Hab Schedule)
2. Critical Design Review (CDR): January 17, 2025
3. Progress Checkpoint: March 7, 2025
4. Final Demonstration and Report: May 30, 2025

Baseline Design Solution

• Structure: Modular trapezoidal truss segments connected via pin-based mechanisms, enabling 0° or 22.5° angles.
• Materials: Full-scale steel for load-bearing demonstrations; 3D-printed ABS for scaled testing.
• Robot: Excahauler robot platform for transport, manipulation, and teleoperated assembly.
• Performance: FEM simulations confirm load-bearing capabilities and safety factor >2.

Verification and Testing

• Destructive and nondestructive testing of 3D-printed and steel components.
• Full-scale assembly and backfill simulation using snow in Fairbanks winter conditions.
• Teleoperation tests for precision alignment and assembly with tracked mobility.

Educational Integration

The project integrates into UAF's systems engineering courses, involving both undergraduate and graduate students in design, simulation, fabrication, testing, and outreach activities.

Additional Information

For more details, please contact Dr. Orion Lawlor at oslawlor@alaska.edu or visit the NASA X-Hab Challenge website.