ICON and BIG: 3D printing on the moon

Building design
ICON's construction system is designed to enable construction on the moon using the moon's own materials. Image source: ICON

ICON's construction system is designed to enable construction on the moon using the moon's own materials. Image source: ICON

ICON, a design and 3D printing company, has – together with BIG – been awarded a contract by NASA to develop space-based design systems. This will support the planned exploration of the moon and beyond. Read all about this futuristic project here.

ICON, a design and 3D printing company, has – together with BIG – been awarded a contract by NASA to develop space-based design systems. This will support the planned exploration of the moon and beyond. Read all about this futuristic project here.

ICON is a company that specializes in advanced construction technologies and large-scale 3D printing. In November 2022, it was awarded a USD 57.2 million contract as part of NASA’s Small Business Innovation Research program. This will enable the company to further develop its space-based construction technology and also aim for the first construction on another planet. The idea is to research and develop space-based construction systems to support the planned exploration of the moon.

ICON’s Olympus system is a multipurpose construction system for lunar and Martian resources that can be used as building materials. This system will help support the efforts of NASA and other organizations to establish a presence on the moon.

Jason Ballard, the co-founder and CEO of ICON, says: “To change the paradigm of space exploration from ‘get there and back’ to ‘stay there’, we need robust, resilient and widely deployable systems that can utilize the local resources of the Moon and other planetary bodies. We are pleased that our research and development work to date has shown that such systems are indeed possible, and we look forward to making this possibility a reality. The end result of this contract will be humanity’s first structure on another world, and that will be a very special achievement.”

According to ICON, advanced construction on earth and in space have a lot in common. The company is a pioneer in the development of methods and technologies to solve construction challenges. These range from affordable housing to life on other planets. As a young and growing company, ICON aims to revolutionize the construction industry both on Earth and in space.

Together with NASA’s Artemis program, ICON plans to take its hardware and software into space with a lunar gravity simulation flight. By working with lunar regolith samples from Apollo missions and regolith simulants, the company hopes to determine the best mechanical behavior for lunar gravity. These findings will help identify future design approaches for the moon for “the broader space community”. This could include critical infrastructure such as landing pads, blast shields as well as roads. In the longer term, critical infrastructure will help build a sustainable economy on the Moon, which could eventually lead to lunar colonization.

Additive manufacturing will be key to 3D construction in space. In this form of 3D printing, software controls the printer. The printer, in turn, applies the material in precise layers to build something. The contract with ICON builds on the funding ICON and architecture firm BIG received in 2020 to develop a way to create 3D printed buildings for life on the moon.

With the NASA funding, ICON will focus on its Olympus system, the first multipurpose lunar construction system. NASA has stated its intention to make the Moon the first near-Earth site for sustained surface exploration. Therefore, a sustainable presence on the moon requires more than just rockets. A robust infrastructure is necessary to ensure better protection from heat, radiation and micrometeorites.

In addition, ICON plans for the program take a “living off the land” approach, i.e., using materials found on the Moon. These efforts are based on the idea of making humanity a spacefaring civilization. To this end, ICON has already developed the world’s first 3D-printed habitat that simulates the surface of Mars. Funded by Jacobs, supported by NASA’s Space Technology Mission Directorate and designed by architecture firm BIG-Bjarke Ingels Group, “Mars Dune Alpha” is located at NASA’s Johnson Space Center. It will help with long-term scientific missions.

However, ICON also works on the ground. The company is known for its advanced 3D printing technology for house construction. It delivered the first 3D-printed homes in the US in 2018, followed by residential projects in Mexico and barracks for the US Army and Air Force. This 3D printing is based on the company’s proprietary Vulcan technology, which is used to produce resilient and energy-efficient homes. As the houses are printed rather than built, they can be constructed more quickly. They also produce less waste and offer more design freedom.

The new, large 3D printer, which was developed together with NASA, would be transported to the moon. There it could use lunar materials to build the moon base. This would eliminate the need to transport building materials to the moon. The aim of ICON is to create a robust, resilient and widely deployable system for construction on other planets and moons.

In addition to ICON and BIG, other architectural firms are also working on building on the moon. For example, SOM and the European Space Agency have designed a settlement for life on the moon that consists of inflatable modules. In addition, the British architecture firm Foster + Partners recently presented a proposal for 3D printing buildings on the moon.

Read more: Can 3D printers also help with residential building extensions?

YOU MAY ALSO LIKE

Bayreuth instead of Verona

Building design

Corona restrictions: Burkhardt-Löffler Managing Director Steffen

On October 2, Burkhardt-Löffler held its first joint in-house exhibition with Weha. According to Weha Managing Director Stefan Deschler, 85 participants had registered for the event. At the in-house exhibition, which was scheduled at short notice, they were able to see new machine developments in the flesh – as well as other innovations. With large machines from Burkhardt-Löffler from all application segments of stone processing […]

On October 2, Burkhardt-Löffler held its first joint in-house exhibition with Weha. According to Weha Managing Director Stefan Deschler, 85 participants had registered for the event. At the in-house exhibition, which was scheduled at short notice, they were able to see new machine developments in the flesh – as well as other innovations.

With large machines from Burkhardt-Löffler from all application segments of stone processing – all equipped with Weha tools – the open day perfectly demonstrated the synergies of the new partnership. In addition, Weha presented several small machines and transport equipment as well as transport vehicles from its product range. And finally, Akemi was the third partner to contribute to the success of the event with a demonstration of its product range.

In the October issue of STEIN 10/20, we reported that Burkhardt-Löffler had already explicitly invited smaller groups to machine demonstrations and factory tours at the company’s sites in Bayreuth and Langenaltheim. With the major event at the beginning of October, the machine manufacturer, together with its new partner Weha, has now provided an important additional impetus for boosting the capital goods business.

The Powerjet 3D waterjet system with the new head developed in-house was of particular interest – mainly because the machine could be experienced in action throughout the day. Software developer Benedikt Maiser also presented the company’s own calibration unit, which can be used to determine the perfect tool center point (TCP). The measuring device compensates for the wobble error of the C-axis and determines the exact distance to the focusing tube.

“We then know exactly how many millimetres we need to compensate in each direction – i.e. for the X, Y and Z axes,” explains Maiser. He uses this to set up the Powerjet 3D in the factory before delivery; the calibration unit is only needed again later if the machine is moved or the customer has had a crash.

In any case, customers appreciate the fact that they can come by with their materials before buying a machine and be shown exactly how to cut them. Maiser and his colleagues can then use the customer information and the material to make recommendations regarding the various machine parameters: from focusing tube and nozzle size and type to sand quantity and type to pump pressure.

Purchasing Manager Michael Hannweber adds with regard to the waterjet machine that the cutting head development is particularly impressive due to the hollow shaft gearbox. This means that the electrical system and high pressure can be fed directly into the 3D head, and there is no longer any need for a pipe spiral or slip ring rotary feed for the electrical signals.

Other visitor magnets were the BAZ 2000 machining center, which, according to Burkhardt-Löffler, has revolutionized the concept of the machining center with automatic suction cup positioning and loading, and the KSL 80 automatic table edging machine, where Weha presented its magnet mounting system, which has been tried and tested for more than 30 years and now has three magnets and is distinguished from competitor products by the fact that the VA buttons of the very quick-clicking triple lock are attached to the base plate instead of the tool.

Burkhardt-Löffler also exhibited the LDZ 2000 K, the compact rotary head saw in monoblock design developed jointly with partner Weha, which we had already presented in STEIN 10/2020. This compact machine can also be set up in companies with limited space. At the in-house exhibition, the machine was shown with the 400/60 UNIV-2 natural stone diamond cutting blade.

Weha also recommended its two new 400 mm Pro-Q and Weramic-yellow blades, which are especially suitable for quartzite and all types of ceramic. Visitors were not yet able to see the planned new KDL-B automatic band edger in action, but according to Stefan Deschler, there have already been many inquiries for it. Thanks to its many years of representing Comandulli machines, Weha has good contacts in the industry, especially with stone processors interested in a belt-driven edging machine.

Many visitors were also interested in the Pantograph 1215 engraving machine presented by GTech company owner Boris Malacko, and the Fuso Canter equipped with a Ferrari loader crane and the compact Roboman Junior crawler vehicle – also with a Ferrari crane – in the outdoor area were surrounded by interested parties throughout the day.

Exhibitor Akemi provided the icing on the cake of an exciting event. Application engineer Otello Piroddi and his colleagues showed, among other things, the new Akepur 250 High Tack for the safe and temperature-resistant bonding of a variety of substructure materials under ceramic, natural and artificial stone.

Another highlight from the construction chemicals manufacturer: the new color paste system, which is particularly suitable for smaller companies and very complex finishing work and, together with the Platinum adhesive, enables an almost inexhaustible variety of colors. The Spectrum Pastes case for up to 60 coloring pastes in 45 gram tubes can be purchased empty and loaded individually. Dry dedusting systems from Weha as well as the BSS 600 wire saw and the CSA 598 industrial band saw system from Burkhardt-Löffler rounded off the extensive in-house exhibition presentation.

Visualization of the Rhine-Ruhr Olympic Stadium: A sustainable athletics stadium as a central component of future-oriented urban development in North Rhine-Westphalia. © planquadrat Elfers Geskes Krämer GmbH

Visualization of the Rhine-Ruhr Olympic Stadium: A sustainable athletics stadium as a central component of future-oriented urban development in North Rhine-Westphalia. © planquadrat Elfers Geskes Krämer GmbH

The Rhine-Ruhr region is facing an exciting new challenge: the vision for an “Olympic Stadium Rhine-Ruhr” could become the starting point for a forward-looking urban quarter.

Planned as a temporary sports venue for the 2040 Olympic and Paralympic Games, the stadium will not only serve as an arena for global sporting events, but also as a basis for the creation of sustainable and resource-conserving urban development. With a clear focus on the circular economy, modular construction and climate-friendly design, this project is setting new standards for the urban planning and architecture of the future.

The “Rhine-Ruhr Olympic Stadium” will not just be a sports facility in the conventional sense. Rather, it will serve as a central building block for the development of a new, liveable urban quarter. The vision is based on the concept of using the stadium as a temporary facility during the Olympic Games and then converting it into a modular, sustainable structure that can continue to be used after the Games. This modular approach allows the stadium to be easily repurposed for later use as housing, office space, sports facilities and kindergartens.

The stadium is at the center of a new quarter that is being built on a former industrial wasteland in the Rhine-Ruhr region. Due to its central location and excellent connections, this brownfield site offers the ideal conditions for the development of a district that will not only offer modern architecture, but also a high degree of sustainability in its structure and use.

The “Rhine-Ruhr Olympic Stadium” has been geared towards sustainability from the outset. It is not only about the environmentally friendly design of the stadium itself, but also about the long-term use and conversion of the entire infrastructure. The concept is based on a modular construction method in which materials and resources are used as efficiently as possible in order to minimize the project’s ecological footprint.

The planned use of the former industrial site is a prime example of sustainable urban development. By consistently applying the principles of the circular economy, the area will be designed as a resource-conserving and climate-friendly living space for the future. After the Olympic Games, the stadium will become a symbol of progressive urban planning that meets the requirements of climate protection and resource conservation.

In addition, the entire district is being planned as a “city of short distances”. This means that living, working and living spaces are connected in such a way that residents have to travel as few distances as possible by car. This encourages the use of public transport and cycle paths, thus helping to reduce CO2 emissions.

A key component of the project is the close collaboration between architecture, urban planning and landscape architecture. The renowned landscape architecture firm geskes.hack from Berlin, together with the architecture and urban planning firm planquadrat Elfers Geskes Krämer GmbH, has developed a concept that sees the “Rhine-Ruhr Olympic Stadium” not only as a sports venue, but also as the center of a green, open space.

A large park is to be created in the center of the new urban quarter, which will serve as a meeting place for residents and visitors. The park will not only be a place for recreation, but also an important part of the district’s environmentally friendly infrastructure. Green spaces, water features and sustainable horticultural concepts will be combined here to improve the microclimate while creating a place for social interaction and the common good.

The use of rainwater management systems and the promotion of biodiversity are also taken into account. The park will thus not only contribute to recreation, but also to the ecological stabilization of the urban space and sustainably increase the quality of life of the residents.

The “Rhine-Ruhr Olympic Stadium” project represents a significant step in the development of sustainable cities. It combines innovative concepts of urban planning and architecture with a sustainable approach that meets the challenges of climate change. The modular construction of the stadium and the integration of the circular economy into the overall development of the district will create a model that shows how sports infrastructure can be designed in a sustainable and resource-saving way.

The new quarter will not only be a modern living space for the population, but also an example of future urban development. It will meet the demand for housing, workplaces and open spaces and at the same time play a pioneering role in terms of sustainability and resource conservation.

The “Rhine-Ruhr Olympic Stadium” is more than just a sports facility. It is the centerpiece of an innovative and sustainable urban project that not only meets the requirements of modern urban development, but also makes an important contribution to climate protection and resource conservation. With a clear focus on sustainability, modularity and the circular economy, this urban quarter will be a model for the cities of the future and create a lasting legacy for generations to come.

Find out more about the 2024 Summer Olympics in Paris and its impact on urban planning and architecture here.