3D-Printed Habitat

Challenge

Phase 3Mid-term Webinar

September 05, 2018

• Welcome/Sponsors and Supporters

• 3D Printed Habitat Challenge – Status Update

• 3D-Printed Habitat Challenge – Levels Review

• Judging Comments

• Construction Level 2 (Hydrostatic Testing)

• Virtual Construction Level 2 (100% Design)

• Construction Level 3 – (Subscale Habitat Competition)

• Q&A

Webinar Agenda

2

Welcome

Lex Akers – Bradley University –

Dean of the College of

Engineering

3

Allied

Organization

Sponsors

Team Agreement

Competitor

TeamsMemo of Understanding (MOU)

Space Act Agreement

4

3D-Printed Habitat Challenge

Status Update

Tony Kim - NASA

5

Significance of the 3D Printed Habitat Challenge

“One of our primary goals for NASA is to Enable Humans to Live and Explore on

Planetary Surfaces. This competition will help us to answer fundamental

questions and possibly to develop capability needed to deliver on that ambition.”

"In-space manufacturing technologies such as the 3D-Printed Habitat technology

are some of NASA's greatest challenges."

“About a month ago I attended a National Science Foundation sponsored

Workshop on Additive Manufacturing for Civil Infrastructure Design and

Construction. This was a world-class international event with a total of 171 people

that attended the workshop, with 17 from industry, 23 from government, and 131

from academia. This particular competition was mentioned many times because

of the excitement it has generated. The world is watching you!”

John Vickers

NASA Space Technology Mission Directorate Principal Technologist

09/22/2017

6

7

Penn State

SEArch+/

Apis Cor

Northwestern

Imagine

Robots

FormForge

PosTech

Colorado

School

of MinesCalTech

ALPHA

Grow

Mars

Zopherus

Mars

Incubator

Kahn-

Yates

Scrappy

X-Arc

AI

SpaceFactory

Hassell&

EOC

BokettoIndia

ThebertonAustralia

8

Media Coverage included clips and videos

appearing in:

Architectural Digest Popular Science

Popular Mechanics Wired

Gizmodo Huffington Post

CNET Wall Street Journal

Gizmag Make

Forbes Yahoo News

More than 1,400 traditional media hits

3DPH Challenge received more than half of the total

hits to our program websites in 2015, ~55K.

The program continues to receive requests from

media outlets asking for information, images,

interviews, etc., almost weekly.

Phase 1: Design | Media Traditional products: media advisory, press

release, web features

Social: A huge push on social media was made

to increase registration, because of which we

gathered the largest pool of applicants CCP had

ever had, at the time.

Outreach: CCP used stage time and an exhibit

space at the NYC Maker Faire to promote the

challenge and to award the Phase 1 checks.

9

The in-person P2:L3 competition was streamed live by NASA 360, as well as captured on the agency’s Snapchat and Instagram accounts, in addition to CCP’s own social channels. Video Views: 404,600Clicks/Actions/Engagement: 64,000Reactions/Comments/Shares: 20,860People Reached / Impressions: 3,263,500

SNAPCHAT – NASA HQ AccountFirst Snap: 203,000

Last Snap: 101,000

INSTAGRAM – NASA HQ AccountFirst Slide: 2,031,851

Last Slide: 591,000

Phase 2: Structural Member | Media

Phase 2 received 374

traditional media hits.

Media Coverage included clips

and videos appearing in:

TechCrunch

Peoria Star Journal

Construction Equipment Guide

Aviation Week

Dallas Morning News

Consumer Electronics

Rocket News 10

3DPH Phase 3 Media Metrics

• 160 media hits, including: PopSci,

USA Today, CNET, MSN, Yahoo,

Forbes, Fox, Engadget, TechCrunch,

Maxim, Esquire, Daily Mail UK, and

ArchDaily.

• 15+ media queries, with more

coming in daily, including NBC

Universal, two TV news interviews,

and journalists in Switzerland, Peru,

Mexico, Singapore, Vietnam,

Germany and others.

• The Top 5 team videos shared on

YouTube have received more than a

half-million views since they were

posted and linked to inside the press

release.

• A single tweet from the @NASA

Twitter account linking to the feature

received 4,800 likes, 1,200 retweets

and 210 comments

• Potential audience from traditional

media of more than 170 million

viewers

• National Geographic published 3

articles mentioning 3DPH in a special

edition Mars issue (July 2018)

• Centennial Challenges video on the

3D Printed Habitat challenge was the

3rd highest watched Marshall

YouTube video in the past three years

with 305,351 views, 110 comments

and 1,339 likes.

Spike in news

coverage after prize

award is

made public

3D-Printed Habitat Challenge

Levels Review

Mike Grichnik - Caterpillar

12

Phase 1 – Design - $50,000 prize purse

Phase 2 – Structural Member - $1,100,000

prize purse

Phase 3 – On-Site Habitat Challenge - $2,000,000 prize

purse!!!

13

NASA’S 3D-Printed Habitat Challenge – Phase 3

• Develop a full scale habitat (92.9 m2 (1000 ft2)) design using

Building Information Modeling (BIM) software and create an

autonomous 3D-Printing system to construct that habitat at 1:3

scale using indigenous and recyclable materials at the head-to-

head competition in April/May 2019

• Teams competing in the Construction Levels are required to

participate in Virtual Construction Levels;

• Teams can choose to participate in the two Virtual Construction

levels only.

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Virtual Construction (BIM)

Level 1 Virtual Construction – 60%

Design Development

Level 2 Virtual Construction – 100% Design Development

Sub-Scale Construction

Level 1 – Foundation

Level 2 – Hydrostatic Testing

Level 3 – Head to Head 1:3 Subscale Habitat

(10.32m2 = 111 ft2)

Phase 3 Competition Levels (Summary)

15

NASA’S 3D-Printed Habitat Challenge – Phase 3

Virtual Construction Levels - $200,000 prize purse overall

• Virtual Construction Level 1 – 60% Design

• MEP & ECLSS Design (LOD 100)

• Structure & Pressure Retaining Walls/Components (LOD 300)

• Virtual Construction Level 2 – 100% Design

• MEP & ECLSS Design (LOD 200)

• Structure & Pressure Retaining Walls/Components (LOD 400)

❖ MEP – Mechanical/Electrical/Plumbing

❖ ECLSS – Environmental Control Life Support System

❖ LOD – Level of Design

16

NASA’S 3D-Printed Habitat Challenge – Phase 3

Construction Levels - $1,800,000 prize purse overall

• Construction Level 1 – Foundation

• Print a foundation within required specifications (2m x 3m with 100 mm slab

thickness)

• Complete other sample prints and evaluations (including slab durability, material

strength and durability)

• Construction Level 2 – Hydrostatic Testing

• Print a foundation and a cylindrical wall with penetrations to demonstrate leak

tightness

• Complete other sample prints and evaluations (including material strength and

durability)

• Construction Level 3 – 1:3 Scale Habitat Printing

• Print a 1:3 scale simplified version of team’s habitat design at the head-to-head

event

• Complete other sample prints and evaluations (smoke test for leakage, a

projectile drop test for robustness, a crush test for ultimate strength and material

strength and durability tests)

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NASA’S 3D-Printed Habitat Challenge – Timeline

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We

are

here

“Late Entry” On-Ramps for the Future Competition Levels

• Construction Level 2 – Hydrostatic Testing - late qualification deadline is Nov. 7, 2018

• Complete the registration requirements

• Complete and submit the mix design, physical samples and test results from the C39 and

C666 tests, and a video clip documenting team’s printing process for assessment by

Bradley University

• Physical samples due by November 21, 2018

• Virtual Construction (BIM) Level 2 – 100% Design

• Complete the registration requirements and submit by the January 16, 2019 deadline

• Construction Level 3 – Subscale Habitat Competition - late qualification deadline is April 1, 2018

• Invitation only – up to eight teams

• Priority is to teams with the best results through the hydrostatic test

• If there are open spots, completing registration requirements and submitting a proposal

along with a BIM model developed to LOD 400 for the structural and pressure retaining

elements and to LOD 200 for MEP & ECLSS is required to be considered – requests will be

evaluated on a rolling basis

• Teams must also complete and submit the mix design, physical samples and test results

from the C39 and C666 tests, and a video clip documenting team’s printing process for

assessment by Bradley University

19

Judges’ Feedback

Pete Carrato – Bechtel

Cory Brugger – HKS

20

Level 1 Judges’ Information

• BIM and Virtual Construction Judges

• 14 Judges: Majority are practicing Architects

• Almost half of the judges are “Space Architects”

• The balance work for major firms designing iconic structures

around the world

• Specialists in Fabrication and Technology

• Head architectural judge nominated by AIA Headquarters

21

Entries to Level 1

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• Virtual Construction (BIM) Level 1 - 60% Design

• 17 Teams submitted complete on time entries

• 100% of the available $100,000.00 prize money awarded!

Virtual Construction Level 1 Top Ten

23

• Level 1 - Virtual Construction

• Great value in having a “Space Architect” on the review of each

project

• Process for providing comments on Virtual/BIM needs improvement

24

Lessons Learned

Construction Level 1 Judges’ Information

• Construction and 3D Printing Judges

• 13 Judges all degreed engineers (more than half with PhD)

• Most participated in Phase 2

• University Professors

• Fellows of the American Concrete Institute

• Researchers in 3D Concrete Printing

• Concrete Material Specialists

25

Entries to Construction Level 1

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• Construction Level 1 – Foundation Test Competition

• 3 Teams entered

• Only 30% of the available $400,000.00 prize money awarded

Construction Level 1 Top Three

27

• General:

• Website organization improved

• Team agreement process improved

• Construction Level 1 - 3D Printing

• Teams should ensure that videos submitted only show safe work

practice

• Team summaries of “interventions” helped with judging

28

Lessons Learned

Construction Level 2

(Hydrostatic Test)

Tracie Prater – NASA

29

Construction Level 2: Hydrostatic Test

• Additively construct a habitat element (reduced-scale) and subject it to

hydrostatic testing

• Print foundation slab on 100 mm sub-base of #57 stone

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• Illustration of wall penetration elements

• No restrictions on team design of these elements provided they

have the required inner diameter and are less than 300 mm long

• Autonomy score based on number and duration of interventions

• Verified based on team-submitted video recording and data log

Construction Level 2: Hydrostatic Test

• Quality evaluation based on principles from ACI 117

• Accuracy of penetration locations (horizontal and vertical) and

alignment

• Measure inner diameter

• Bonus points awarded for roof

• Hydrostatic test

• Fill habitat element at rate of at least 10 L/min to a depth of 500 mm

• Filling device should not extend below 1.25 m depth

• Record (video and accompanying measurement) of leakage

over 15 minute period:

• after reaching a depth of 500 mm

• after reaching a depth of 1.25 m

• Teams can choose to pre-soak habitat element for up to 24 hours

prior to test (but must submit a video of this entire period)

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Construction Level 2: Hydrostatic Test

• Focus is on creation of construction materials from indigenous

materials and mission waste (polymer recyclables which would

otherwise be “nuisance” materials)

• As in phase II, a sliding materials scale rates construction material

selection based on relevance to planetary missions– Teams are no longer penalized for use of imported materials (those that would be

transported from earth specifically for construction purposes) as they were in phase II,

but indigenous materials are scored higher than nonindigenous materials on the sliding

scale

• No penalty for water

• Material feedstock must be a blend suitable for the competition (see FAQ 3.12)

– Polymer scale is based on frequency of use of polymeric materials in packaging for the

International Space Station (ISS)

– Aggregate scale is based on relative availability of materials on the planetary surface

Materials

Basalt, considered an indigenous material, is

rated highly on the sliding scale for habitat

construction materials

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Materials

34

Materials

3DP Factor calculated based on weighted average

35

36

Materials scoring

The material mix will be assigned a score by summing the products of the 3DP

factor of each material and the amount of that material (by %weight) present in

the formulation.

Video and documentation evidence of the material selections and mixing

process will be required for the judges to be able to validate the mix and award

the appropriate points.

For phase III, a maximum of 100 of 1100 points at each construction level will

be allocated to material selection.

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• Additional materials testing is required only if

material mix has changed since previous submission

– Teams must submit information on new material

mix (constituent materials and percentages by

weight) sufficient to assign a new 3DP factor

– Durability testing of specimens (freeze/thaw test

per ASTM C666) from certified test lab

• This test takes 2-3 weeks to run.

• Scores assigned based on reported

durability factor

– Compression test per ASTM C39

• If materials are unchanged from the previous level’s

formulation (and the previous level’s formulation was

deemed acceptable by the judges), they can carry

over to this level

Image credit: CTRE, Iowa State

University

Construction Level 2: Hydrostatic Test

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– Autonomy in printing (based on video submission and data log): 225 points

– Autonomy in penetration placement and sealing (based on video submission and

data log): 225 points

– Quality: 100 points

• 80 points for positioning the penetrations

– +/-25 mm for position

– +/- 3 degrees for alignment

• 20 points for ID accuracy (within +/- 25 mm)

– Material selection of feedstock blend: 100 points

– Hydrostatic test: 125 points based on performance (leak rate at 1.25 m and 500

mm fill levels)

– Material durability: 75 points

– Compressive strength: 50 points

– Documentation: 100 points

– Roof (bonus): 100 points

• Is the roof present and practical?

Construction Level 2: Hydrostatic Test - Scoring

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✓ Summary of changes in printing process and approach since prior level (captured in

written report)

✓ Document material mix for level 3 and calculate 3DP factor

✓ can indicate that material formulation is unchanged

✓ If changed, certified test lab must submit results of freeze/thaw testing of three

samples and compression testing of one sample to Bradley University

✓ Test samples must also be sent to Bradley University (compression sampl

post-test, durability specimen post-test, and core sample

✓ If changed, submit SDS for material constituents not included in prior level’s

material formulation

✓ If changed, provide documentation of any changes to the mixing process

✓ Documentation of leak test, penetration placement, penetration alignment, and inner

diameter measurement

✓ Video (must also include pre-soak if used)

✓ Data log

✓ Measurements

✓ Discussion of roof design if team exercises this option (part of written report)

✓ Autonomous operation assessment (part of written report) –note number, nature,

and durations of remote and human interventions during printing and penetration

placement 39

Construction Level 2: Hydrostatic Test: Submission

Prizes for Construction Level 2

• The top 8 teams may receive a cash prize. Non

US teams are not eligible for a cash award but

will be recognized for their position in the

competition.

• A maximum of $600,000 is available.

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Virtual Construction Level 2

(100% Design)

Cory Brugger – HKS

41

Phase 3 Virtual Construction Level 2Construction Documentation (100% Design Complete) Level

• Model review sessions will be evaluating Completeness of Model, BIM Use

functionality, Aesthetic Representation, Realism of 4D Model

• (3D BIM) Habitat Modeling: It is the metadata integrated model and design review

process used to depict an accurate representation of physical conditions,

printing environment, and assets of facility.

• Optional (4D BIM) Construction Sequencing

• Optional (4D BIM) Equipment Flow

• Optional (4D BIM) Virtual Mockup

• 100% model review the MEP and ECLSS shall be at LOD 200 and the

structural pressure retaining components shall be at LOD 400.

• Level of Development shall be judged based on the publicly available guide

lines provided by the BIM Forum http://bimforum.org/lod/ .

• Submission must be provided to Bradley by January 16, 2019

• 3 teams with highest scores awarded prize proportional to score for total amount

of up to $100k

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Judging Categories for Virtual Construction

Level 2 – 100% Model Review

• BIM Completeness: 250 maximum points

• Functionality of Design: 500 maximum points

• Aesthetics : 250 maximum points

• Bonus:

– 4D Model Realism : 200 maximum points

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3D PRINTED HABITAT:

MINIMUM PROGRAM REQUIREMENTS

• 1000 ft2 (~93 m2) of livable space

• Three 46 ft3 (~4.3 m2) ECLSS spaces (environmental

control & life support systems)

• Structural and MEP layout

• Exterior wall penetration

• Functional space planning for 4 astronauts for one year

44

Prizes for Virtual Construction

Level 2

• The top 3 teams may receive a cash prize. Non

US teams are not eligible for a cash award but

will be recognized for their position in the

competition.

• A maximum of $100,000 is available.

45

Construction Level 3 – Subscale

Habitat Competition

Mike Grichnik – Caterpillar

46

Subscale Habitat Competition

• Face to face competition - invitation only

• Limited to no more than eight teams

• $800,000 in prize money available with a

$500,000 top prize!

• More than just printing a 1/3 scale habitat –

requires significant work by the teams leading

up to the actual event

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Caution for Teams in the

Full Competition

The 1/3 scale model of the habitat must be printed

in a 4.5 meter by 4.5 meter area at the head to

head competition.

Total time allocated to printing activities is 30 hours

over three days

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“Pre-work” to Consider

• Optional pre-printed components per rule 8.2.11

• Material mix and durability test results

• Three bending test samples per rule 8.9 printed before

the competition and brought for testing

• Documentation for judge review per rule 8.11

• A BIM model with structural and pressure retaining

elements at LOD 400 and to LOD 200 for MEP & ECLSS

which corresponds to the structure that will be printed at

the event submitted along with the proposal defined in

rule 9.2.

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Facility Overview• Peoria, IL – 2.5

hours SW from

Chicago

• Metro area

population –

375,000

• Home of Bradley

University and

Caterpillar

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• 720 acres for

training and

demonstrations

• 150,000 square

feet of arena under

roof (2)

• First demonstration

– 1971

• 20,000 visitors

hosted annually

Facility Overview

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• Printing and testing will be in indoor

arena

– Compacted soil floor

– Arena is ventilated but not air

conditioned

– Power provided based on requests (60

Hz)

• Printing equipment and component

materials should be shipped in

weatherproof containers

• Event is open to the press and to select

members of the public

Facility Overview

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• April 22-26 – team shipments of material can be received at the

facility (weatherproof containers)

• April 29-30 – teams will have two eight hour sessions to set up,

prep, and test printers before competition

• May 1-3 – teams will have three ten hour sessions to print their

habitat with an additional 30 minutes of startup/cleanup time at the

beginning/end of day

• Friday, May 3 – Strength testing of beams per rule 8.10

• Saturday, May 4 – final evaluation of printed habitats via rules 8.4,

8.6, 8.7, and 8.8; deconstruction and removal of printers from arena

Tentative Timeline

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Questions and Answers

www.Bradley.edu/challenge

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