Could these big expandable habitats help humanity settle the moon and Mars? – Space.com

COLORADO SPRINGS Max Space wants to help humanity expand into the final frontier.

The startup is developing a range of inflatable space habitats, the largest of which could provide as much internal volume as a sports stadium. These plans, which Max Space unveiled on Tuesday (April 9) here at the 39th Space Symposium, are designed to help our species make the difficult leap off its home planet.

"The problem with space today is, there isn't enough habitable space in space," Max Space co-founder Aaron Kemmer said in a statement on Tuesday. "Unless we make usable space in space a lot less expensive, and much much larger, humanity's future in space will remain limited."

Related: Living on the moon: What it would be like (infographic)

Back in 2010, Kemmer co-founded the off-Earth manufacturing company Made In Space, which has sent multiple 3D-printing devices to the International Space Station (ISS) over the years. (Made In Space was acquired by Redwire in 2020.)

He says that experience helped convince him that expandable habitats are the future, citing one of the machines Made In Space modified for use on the ISS.

"It's like a three-story system on Earth, and all the engineering wasn't to make it work in space it was actually to get it down to a locker [size], just because there wasn't enough real estate in there," Kemmer told Space.com in an interview here at the symposium on Tuesday.

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Expandable habitats, as the name suggests, launch in compressed form to fit inside rocket fairings but increase in size greatly when deployed in space. They therefore offer much more bang for the buck volume-wise than traditional "tin can" module designs.

An expandable habitat with 100 cubic meters (3,530 cubic feet) of pressurized volume, for example, would be "at least an order of magnitude cheaper" than a comparable metallic one, Kemmer said. (For perspective: The ISS offers 388 cubic meters, or 13,700 cubic feet, of habitable volume, not including the space provided by visiting vehicles.)

This is not a sci-fi concept; three expandable module prototypes are actually circling Earth right now. They are Genesis 1 and Genesis 2, which are free fliers that launched in 2006 and 2007 respectively, and the Bigelow Expandable Activity Module (BEAM), which has been attached to the ISS since 2016.

All three were built by Nevada-based company Bigelow Aerospace, which closed its doors in 2020. The pressure-restraining hulls for Genesis 1 and Genesis 2 were designed and manufactured by Thin Red Line Aerospace, a small Canadian company run by Maxim de Jong Max Space's other co-founder.

The new startup, which has been in operation for about a year, is commercializing Thin Red Line Aerospace technology, Kemmer and de Jong said. But that tech isn't just a Genesis retread.

"It's a very, very, very different approach, where you're just putting fibers in an uncoupled scenario where they don't conflict with one another," de Jong told Space.com on Tuesday. The result, he and Kemmer said, is a cost-effective module that expands in a predictable and reliable way, and is highly scalable to larger sizes.

The new tech will get its first off-Earth test just two years from now, if all goes according to plan: Max Space has booked a spot on a SpaceX rideshare launch in 2026.

That mission will send a module the size of two large suitcases to orbit. However, that's the habitat's compressed configuration. Once deployed, it will expand to a pressurized volume of 20 cubic meters (706 cubic feet).

This deployment will set a new record for expandable habitats. The two Genesis prototypes both feature 11.5 cubic meters (406 cubic feet) of internal volume, while BEAM has 16 cubic meters (565 cubic feet).

Max Space has already built a full-size prototype of the first flight unit, which the company is using for ground testing, Kemmer said. It has started manufacturing the flight vehicle, which will not feature life-support systems but will have the same shielding and strength as human-rated versions.

Related: NASA's moon-orbiting space station will be claustrophobic, architect says

Max Space plans to keep moving fast after this pioneering module makes it to orbit. The startup aims to launch its first 100-cubic-meter (3,531 cubic feet) module in 2027 and to get a 1,000-cubic-meter (35,314 cubic feet) behemoth up by 2030. Even larger variants could potentially launch thereafter, aboard SpaceX's Starship megarocket or Blue Origin's New Glenn vehicle, the company said.

The goal is to provide a variety of destinations to a range of customers, from pharmaceutical companies that want to mass-produce medicines in microgravity to commercial space stations that want to expand their living space all the way to movie studios looking to film in orbit.

"We have several space production companies that we're talking to," Kemmer said. The company has already secured some customer contracts, including from the U.S. Space Force, he added.

But Earth orbit will be just the starting point for Max Space modules, if all goes according to plan.

"My dream is to have a city on the moon before I die," Kemmer said. "So I look at this like, this is going to be the habitat, the structures, that are going to go inside the lava tubes buried under the [lunar] surface."

The company's modules would then make their way to Mars, if all goes well, for Max Space wants to be a key enabler of off-Earth settlement. Indeed, that's why Kemmer and de Jong founded the company to help humanity extend its footprint out into the solar system.

"That was the entire reason," Kemmer said.

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Could these big expandable habitats help humanity settle the moon and Mars? - Space.com

Maryland: Building on an Aerospace Legacy: Maryland companies navigate the commercial space race. – Site Selection Magazine

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n incubator of aerospace and aviation engineering going back nearly a century, the Lockheed Martin plant at Little River, Maryland, has a storied history. It was there that the Glenn L. Martin Companys developed the B-26, a medium-range bomber that flew more than 100,000 sorties during World War II. Parts of Gemini and Apollo spacecraft came out of the plant decades later. Shuttered last year as part of a corporate re-organization, the cavernous facility in fairly short order has received a new lease on life.

Literally. Rocket Lab, an agile player in the evolving commercial space game, agreed in November to rent and refurbish 113,000 sq. ft. from Lockheed Martin for a Space Structures Complex. To assist with project costs, the Maryland Department of Commerce is providing a $1.56 million repayable loan through its Advantage Maryland program. Slotted to create 65 new jobs, its a project the state government seemed eager to get.

With our states close proximity to several federal and defense agencies, combined with Marylands abundance of talented tech and engineering workers, said Commerce Secretary Kevin Anderson in a statement, this facility is sure to bring much success to both Rocket Lab and Marylands innovative space industry.

Founded in New Zealand in 2003 and headquartered now in Long Beach, California, Rocket Lab is what founder and CEO Peter Beck calls a one-stop space shop. It provides satellite design and manufacturing for both the U.S. government and private clients and launch services to customers that include NASA, the U.S. Space Force and the National Reconnaissance Office. Rocket Lab technology went into the James Webb Telescope, developed in part at NASAs Goddard Space Flight Center in Greenbelt, just northwest of Washington, D.C.

Most aerospace companies, youre either a satellite guy or youre a rocket guy, Beck tells Site Selection. Were both, he says. So, when a customer comes to us, we can build a satellite, then we can launch the satellite and we can even operate the satellite with them.

Among recent, high-profile projects, a Rocket Lab Electron rocket sent NASAs CAPSTONE CubeSat on a path toward the moon from the companys Launch Pad 1 in New Zealand. CAPSTONE has settled into a pioneering lunar orbit, the same orbit planned for Gateway, a small space station from which NASA plans to return humans to the Moon.

We operated the spacecraft, says Beck, until it was time to turn it over to NASA.

Rocket Labs Middle River facility is to focus on composites and composite structures Were the only company, says Beck, thats building fully carbon composite launch vehicles with an eye toward building ever larger rockets.

For us to be able to pick up a facility of this size, one with large, open spaces and a hugely thick foundation, is incredibly rare, Beck says of the Lockheed Martin complex.

The facility offers other advantages, as well. Barge access will allow Rocket Lab to float spacecraft and rockets down Chesapeake Bay to its installation at NASAs Wallops Flight Facility at Wallops Island, Virginia. Wallops, says Beck, will be the exclusive launch platform for the companys Neutron rocket, now in development.

Having manufacturing capability so near the launch site is super, super helpful, he says.

The Space Structures Complex will expand Rocket Labs existing footprint in Maryland, where the company already operates a manufacturing facility for satellite separation systems and CubeSat dispensers in Silver Spring. Its experience in Maryland, Beck believes, bodes well for Rocket Labs expansion there.

Theres a deep aerospace community with lots of experience. Theres also a really deep composites industry. You can have a great building, but youre going to need to fill it with the best people to be successful, and what weve seen is a culture of getting stuff done that really aligns with our companys core values.

Were super lucky, Beck believes, because not just in Maryland but down the road at Wallops Island weve always been greeted with warmth and, quite frankly, excitement. Theyve really rolled out the red carpet, and its been a great experience for us.

Genesis: Beyond the Logo

Like Rocket Labs, Genesis Engineering has its fingers in numerous pies, opportunities being what they are in the new Wild West of space travel. Unlike Rocket Labs, Genesis is Maryland-born and bred. And Genesis, let it be known, engineered a singular coup in the history of product placement.

The Genesis logo, attached to Space Shuttle Discovery

Photo courtesy of Genesis Engineering

As astronaut Mike Massimino dangled outside Space Shuttle Discovery during a 2009 spacewalk, a NASA camera swung around to capture what looked like a bumper sticker. Blue letters on a white background, it read Genesis Engineering. Today, that memento hangs on a wall at a Genesis conference room at the companys headquarters in Lanham, near NASAs Goddard Space Flight Center.

That was the last time they allowed a contractor to fly their logo, says Robert Rashford, Genesis founder and CEO. We got free advertising for two days in space. Then they said, No more of that.

Rashford himself is an interesting story. The native of Kingson, Jamaica, emigrated to the U.S. in 1978, earning a degree in mechanical engineering from Temple University. After landing his first aerospace job with the space division of RCA in New Jersey, he moved to Maryland for a position with Fairchild Space and Defense, where he says he learned to build tools employed by spacewalking astronauts. Banking that experience, Rashford struck out on his own. He founded Genesis in 1993, seeding the new companys bank account with $350.

Today, Genesis employs about 200 people spread across four buildings in Lanham. The work that earned it that bumper sticker included supplying NASA with tools and tool lockers for stowing all manner of space gear packed to exacting specifications.

We also wrote scripts for the astronauts on the cadence of the spacewalk. That was our bread and butter for several years. Then, we designed and built hardware for the James Webb Telescope.

Having manufacturing capability so near the launch site is super, super helpful.

Peter Beck, Founder & CEO, Rocket Labs

The granular knowledge Genesis gathered from supporting shuttle spacewalks inspired one of the companys most ambitious projects to date. Who knew that spacesuits designed for EVAs (Extravehicular Activities), are essentially one-size-fits all? Ill-fitting suits, says Rashford, can cause skin abrasions and joint problems. Heating and cooling systems can leak water, cutting spacewalks short. The Genesis Single Person Spacecraft, (SPS) designed with the International Space Station, NASAs Gateway program and space tourism in mind, is a self-propelled module that a spacewalker would board to operate outside the mothership sans spacesuit and without the lengthy hours of pre-breathing required to prevent getting the outer space version of the bends.

You can eliminate all of that, says Rashford, because the pressure inside the vehicle is the same as inside the spacecraft.

Orbital Reef, conceived as a space-based business park, is a potential partner for SPS, although Rashford suggests that project led by Blue Origin is being slow-walked due to other Blue Origin priorities. Genesis, says Rashford, is looking for an investor to see SPS to the finish line.

In the meantime, Genesis is developing its first CubeSat, a miniaturized satellite for space research, creating a propulsion system for a private customer and bidding on a billion-dollar contract with Goddard to produce mass spectrometers for space applications.

We feel the time is right to do it, Rashford says. We have the staff, the confidence, the know-how and the partnerships. We think we stand a good chance of winning that contract because of what we have to offer.

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Maryland: Building on an Aerospace Legacy: Maryland companies navigate the commercial space race. - Site Selection Magazine