Description: Thermoplastic composites can be reformed, repaired, and welded utilizing thermal processes, providing lunar missions a means of repurposing lander components into equipment that can be used for in-situ resource utilization (ISRU) activities. By reforming spacecraft components after arriving on the Moon, equivalent system mass (ESM) is minimized, allowing for additional equipment to be transported. Lynntech and the University of Washington propose an innovative means of reforming, repairing, and welding thermoplastic composites using an automated process capable of producing repeatable results, allowing for the process to be certified and employed across various industries, such as aerospace and automotive. The team will: 1) identify lander components suitable for thermoplastic composite construction, and 2) create designs for a handcart that can be constructed from the lander's thermoplastic composites after arriving on the Moon. The handcart will enhance lunar activities by providing the astronauts with a means of increasing their carrying capacity on missions. The cart can be used to carry additional oxygen, power systems, tools, and lunar regolith. Solar panels can be equipped to the cart, allowing for continuous energy harvesting during lunar extravehicular activities. The research team will utilize finite element analysis, multiphysics modeling, and empirical methods to develop the thermoplastic composite process and designs for the lander components and handcart. The process developed can be adapted for other thermoplastic components if NASA desires an alternative to the handcart.

Benefits: The proposed R/R&D activities will result in a general-purpose, certifiable autonomous thermoplastic reform, repair, and welding process that can be used by astronauts to repurpose thermoplastic components of their spacecraft into tools and equipment after reaching the Moon or other destination. Likewise, the process can be used in the construction and repair of aircraft and spacecraft produced by NASA, reducing cost and improving component performance. In addition to the development of the thermoplastic repurposing process, the project aims to develop designs for a lunar handcart that can be constructed from the lunar lander's thermoplastic panels and braces once the astronauts arrive on the Moon. The handcart will be a boon for lunar explorers, as it will increase their carrying capacity, allowing them to carry additional oxygen, power, tools, and equipment to extend the duration of lunar extravehicular activities. The cart can be used to transport lunar regolith and Moon rocks during in-situ resource utilization activities performed by astronauts. Once space-certified electric vehicles and robotic dogs are transported to the Moon, the handcarts can be pulled by these systems much like a trailer. Solar panels can be affixed atop the handcarts, allowing for energy harvesting during excursions, providing astronauts and electric vehicles with a continuous input of power, further increasing mission duration. The Moon's lower gravity further increases a cart's usefulness and carry capacity, as more mass can be transported compared to earthly applications.The proposed R/R&D activities will result in a general-purpose, certifiable autonomous thermoplastic reform, repair, and welding process that can be used across industries, such as aerospace and automotive. Since there are currently no certified thermoplastic repurposing processes available to industry, the use of thermoplastics across many sectors has been limited. By creating a certifiable process, the use of thermoplastics will be more widely adopted. Repurposing, repair, and reuse of thermoplastics is more environmentally friendly, energy efficient, and economical than recycling or throwing away plastics; by providing industry with a repurposing option, conditions on Earth could be improved.