The media advisory/news release about Aluula and its role in NASA’s (US National Aeronautics and Space Agency) proposed moon habitat was received via email back in June 2024. I’m glad I waited as I found a very detailed story by Devin Coldeway about the proposed moon habitat that wasn’t published until late July.2024.
First, some early news about Aluula and NASA, from an April 22, 2024 article by Nelson Bennett for Business in Vancouver,
A Victoria [British Columbia, Canada] composite materials company that developed a super-strong, lightweight polyethylene material used in a range out outdoor recreation equipment could soon be used by astronauts in space in inflatable space habitats.
Max Space, an American company that is developing expandable space habitats, is now incorporating composite materials made by Aluula Composites (TSX-V:AUUA).
Aluula’s innovation was developing a heat fusion process for working with ultra-high-molecular-weight polyethylene (UHMWPE) to make a super-tough lightweight material.
It is being used as part of a custom laminate that adds strength and durability to structural elements to the Max Space habitat, “making it possible to create a large living and working area at a fraction of the weight and transport costs of traditional crew modules,” Aluula said in a press release.
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Here’s more about the NASA mission from a January 3, 2024 NASA news release,
NASA announced Tuesday [January 2, 2024] updates to its Artemis campaign that will establish the foundation for long-term scientific exploration at the Moon, land the first woman and first person of color on the lunar surface, and prepare for human expeditions to Mars for the benefit of all. To safely carry out these missions, agency leaders are adjusting the schedules for Artemis II and Artemis III to allow teams to work through challenges associated with first-time developments, operations, and integration.
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With Artemis, NASA will explore more of the Moon than ever before, learn how to live and work away from home, and prepare for future human exploration of the Red Planet. NASA’s SLS (Space Launch System) rocket, exploration ground systems, and Orion spacecraft, along with the human landing system, next-generation spacesuits, Gateway lunar space station, and future rovers are NASA’s foundation for deep space exploration.
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The June 20, 2024 Aluula media advisory/news release (received via email) describes the company’s involvement this way,
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A small company on Canada’s west coast is playing a big role to help astronauts return to the moon in 2026.
ALUULA Composites recently signed an agreement with Max Space, an American company, to use its innovative composite material to build space habitats on the moon. The company’s ultra-high-molecular-weight polyethylene (UHMWPE) laminate will be used to create a large living and working area for NASA’s astronauts when they return to the moon in September 2026.
The innovative material was selected because it has eight times the strength-to-weight ratio of steel and is extremely durable, which is ideal for space travel.
The first Max Space inflatable space habitat is slated to launch with SpaceX in 2026. The Max Space inflatables can be delivered into space in very small packages and then unfolded and expanded to create a much larger work space.
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Emily Mertz’s July 16, 2024 article for Global TV news provides a few more details, Note: Links have been removed,
A small West Coast company is helping astronauts return to the moon in 2026. ALUULA Composites has signed on to provide its durable, lightweight fabric to build space habitats.
The Max Space inflatables can be transported in very small packages and then expanded to create a much larger workspace.
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“It [Aluula’s ultra-high-molecular-weight polyethylene (UHMWPE) laminate] was actually originated by a bunch of engineers, chemists and wind sport enthusiasts. When you’re on the water, using a kite or a wing, you need something that’s very durable and very light and it was developed in that context.” [said ALUULA president and CEO Sage Berryman]
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The B.C. company, which is fairly young — it started in 2020 — is also committed to sustainability.
“It’s the first material that’s been done as a composite not using glues, so that also allows it to be recycled at the end of its useful life, which is pretty different in a material that’s polyethylene — plastic-based,” Berryman said.
“Our goal is to make products that are able to be fully circular and that’s an exciting thing as well.”
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“Having these opportunities to have these unique materials in unique applications is really exciting. And when you start talking about a project that’s not a huge project for us, but it’s huge in its meaningfulness, when you’re working with Max Space that’s working with NASA that’s going up on SpaceX, it is exciting,” she said.
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Mertz’s July 16, 2024 article contains some news videos and about the project and related space information.
Space habitat details
Devin Coldeway’s July 27, 2024 article for TechCrunch and republished yahoo! news tells a fascinating story about space habitats with a special emphasis on the one being developed for NASA’s Artemis campaign, Note: Links have been removed,
Max Space reinvents expandable habitats with a 17th-century twist, launching in 2026
Working and even living in space has shifted from far-off fantasy to seemingly inevitable reality, but the question remains: what exactly will the next generation of space habitation look like? For Max Space, the answer is clear, and has been for decades — centuries, even. A new generation of expandable habitats could offer both safety and enough room to stretch your legs, and the first one is going up in 2026.
The startup is led by Aaron Kemmer, formerly of Made in Space, and Maxim de Jong, an engineer who has studiously avoided the limelight despite being the co-creator of expandable habitats like the one currently attached to the International Space Station.
They believe that the breakout moment for this type of in-space structure is due to arrive any year now. By positioning themselves as a successor to — and fundamental improvement on — the decades-old designs being pursued by others, they can capture what may eventually be a multi-billion-dollar market.
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Expandable habitats go back a long ways, but their first real use was in the TransHab project at NASA in the 1990s, where the fundamental approach was developed.
Contrary to their appearance, expandables aren’t just big balloons. The visible outer layer is, like with many spacecraft, just a thin one to reflect light and dissipate heat. The structure and strength lie inside, and since Transhab the established convention has been the “basket weave” technique.
In this method, straps of kevlar and other high-strength materials are lined up in alternating directions and manually stitched together, and upon expansion form a surface like a woven basket, with the internal pressure distributed evenly across all the thousands of intersections.
Or at least, that’s the theory.
De Jong, through his company Thin Red Line Aerospace, worked successfully with Bigelow Aerospace to develop and launch this basket-weave structure, but he had his doubts from the start about the predictability of so many stitches, overlaps, and interactions. A tiny irregularity could lead to a cascading failure even well below safety thresholds.
“I looked at all these straps, and as a field guy I was thinking, this is a cluster. As soon as you’re over or under pressure, you don’t know what percentage of the load is going to be transferred in one direction or another,” he said. “I never found a solution for it.”
He was quick to add that the people working on basket-weave designs today (primarily at Sierra Nevada and Lockheed Martin) are extremely competent and have clearly advanced the tech far beyond what it was in the early 2000s, when Bigelow’s pioneering expandable habitats were built and launched. (Genesis I and II are still in orbit today after 17 years, and the BEAM habitat has been attached to the ISS since 2016.)
But mitigation isn’t a solution. Although basket-weave, with its flight heritage and extensive testing, has remained unchallenged as the method of choice for expandables, the presence of a sub-optimal design somewhere in the world haunted De Jong [sic], in the way such things always haunt engineers. Surely there was a way to do this that was strong, simple, and safe.
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Mylar and Bernoulli
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As he [de Jong] balefully contemplated the helium-filled Mylar, something about it struck him: “Every volume that you can put something in has load in two directions. A kid’s Mylar balloon, though… there are two discs and all these wrinkles — all the stress is on one axis. This is a mathematical anomaly!”
The shape taken by the balloon essentially redirects the forces acting on it so that pressure really only pulls in one direction: away from where the two halves connect. Could this principle be applicable at a larger scale? De Jong [sic] rushed to the literature to look up the phenomenon, only to find this structure had indeed been documented — 330 years ago, by the French mathematician James Bernoulli.
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This was both gratifying and perhaps a little humiliating, even if Bernoulli had not intended this interesting anomaly for orbital habitation.
“Humility will get you so far. Physicists and mathematicians knew all this, from the 17th century. I mean, Bernoulli didn’t have access to this computer — just ink on parchment!” he told me. “I’m reasonably bright, but nobody works in fabrics; in the land of the blind, the one eyed man is king. You have to be honest, you have to look at what other people are doing, and you have to dig, dig, dig.”
By forming Bernoulli’s shape (called an isotensoid) out of cords, or “tendons,” every problem with expandables more or less solves itself, De Jong [sic] explains.
“It’s structurally determinant. That means if I just take a cord of a certain length, that will define all the geometry: the diameter, the height, the shape — and once you have those, the pressure is the PSI at the equator, divided by the number of cords. And one cord doesn’t affect the others, you know exactly how strong one cord needs to be; everything is predictable,” he said.
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It’s stupidly simple to make.”
All the important forces are simply tension on these cords (96 of them in the prototypes, each rated to 17,000 pounds), pulling on anchors at either end of the shape. And as you might guess from suspension bridges and other high-tension structures, we know how to make this type of connection very, very strong. Gaps for docking rings, windows, and other features are simple to add.
The way the tendons deform can also be adjusted to different shapes, like cylinders or even the uneven interiors of a Moon cave. (De Jong [sic] was very excited about that news — an inflatable is a highly suitable solution for a lunar interior habitat.)
With the pressurized structure so reliable, it can be skinned with flight-tested materials already used to insulate, block radiation and micrometeoroids, and so on; since they aren’t load bearing, that part of the design is similarly simple. Yet the whole thing compresses to a pancake only a few inches thin, which can be folded up or wrapped around another payload like a blanket.
The biggest inflatables anyone has made, and we did with a team of five people in six months,” De Jong [sic] said — though he added that “the challenges of its correct implementation are surprisingly complex” and credited that team’s expertise.
What De Jong [sic] had done is discover, or perhaps rediscover, a method for making an enclosure in space that had comparable structural strength to machined metal, but using only a tiny fraction of the mass and volume. And he lost no time getting to work on it. But who would fly it?
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Thin Red Line has seen plenty of its creations go to orbit. But this new expandable faced a long, uphill battle. For spaceflight, established methods and technologies are strongly favored, leading to a catch-22: you need to go to space to get flight heritage, and you need flight heritage to go to space.
Falling launch costs and game investors have helped break this loop in recent years, but it’s still no simple thing to get manifested on a launch vehicle.
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… Max Space, a startup built specifically to commercialize the new approach — the name is both a reference to having more space in space, and a tribute to (Maxim) De Jong, whom Kemmer [Aaron Kemmer, cp-founder] thought deserved a bit more recognition after working for decades in relative anonymity (“which suits me just fine,” he noted).
Their first mission will launch in 2026 aboard a SpaceX rideshare vehicle, and act as a proof of concept so they can get flight heritage, which is one advantage extant expandables have over isotensoids.
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If you have the time and the interest, Coldeway’s July 27, 2024 article is a good read with a lot of informative images such as this one
Caption: The 20-cubic-meter habitat deflated to a 2-cubic-meter pancake, or “planar configuration.” Credit: Max Space? [downloaded from https://ca.news.yahoo.com/max-space-reinvents-expandable-habitats-150000556.html]
One last thing, it looks like the deal was originally announced with Thin Red Line Aerospace in a December 12, 2022 Aluula news release,
We are excited to announce that ALUULA Composites is supporting Thin Red Line Aerospace in the development of leading-edge application hardware for future NASA lunar and Mars missions.
“Their unique range of technical attributes combined with impressive strength to weight ratio specifications, make ALUULA Composite materials very well suited to the demanding requirements of technology in space.” Stated Thin Red Line Aerospace President, Maxim de Jong.
“We continue to find new and exciting ways in which our process enables and enhances composite materials to satisfy very specific technical objectives, and our work with Thin Red Line is another great example of what is possible with our materials and unique expertise.” Said ALUULA Composites COO, John Zimmerman.
Air & Cosmos International Announcement: https://aircosmosinternational.com/article/aluula-composites-selected-for-future-nasa-lunar-and-mars-missions-3364
JEC Composites Announcement: https://www.jeccomposites.com/news/aluula-composites-selected-for-future-nasa-mars-missions/
I guess they needed one more player, i.e., Max Space, to get ready for the launch.