The proposed multi-Center collaboration seeks to combine computational simulations (ARC) with experimental synthesis and characterization (LaRC) to develop a recyclable feedstock based on a hybrid polymer-microparticle system that can be reversibly assembled via click chemistry. This material could be integrated into the launch vehicle as secondary structure, which could then be recycled to feedstock and repurposed for other mission needs once their utility is fully realized. In particular, this would be achieved by reducing the component (e.g., a shelf surface) to a feedstock material through only modest heating to unclick the microparticles. The recycled feedstock could then be reconfigured into a new component by clicking the microparticles back together.

Missions beyond low-Earth orbit will have increasing demands on payload weight and evolving needs. Long duration exploration vessels will therefore benefit from in-space manufacturing where articles can be generated on demand. Additionally, the ability to return articles to feedstock after utilization for additional use, without a significant energetic cost, will reduce payload and energy requirements without sacrificing mission capabilities. Recently, the use of in-space manufacturing with recyclable feedstocks for a nominal 1,100-day mission to Mars and back was determined to enable a significant reduction in maintenance parts. An estimated 30% of all components are amenable to in-space manufacturing, which would yield a 97.7% reduction in the required spare parts mass.