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IAC-24- E5.1
Hybrid-Module Design for Human Lunar Colonization
Corrado Testia*, David Nagya, Joshua Dowa, Andrew Bonda, Olga Bannovaa
a SICSA, Department of Mechanical and Aerospace Engineering, University of Houston, 4726 Calhoun Rd, Houston,
Texas 77204
* Corresponding Author, ctesti@cougarnet.uh.edu
Abstract
Establishing a permanent human presence on the Moon is a crucial step towards becoming an interplanetary species
and enabling further exploration of the Solar System. This paper presents a comprehensive design approach for the
initial modules that will form the foundation of a lunar colony at the South Pole, accommodating the first crew of
four astronauts. Our multidisciplinary team conducted an extensive study of historical literature and state-of-the-art
human habitat designs to develop an innovative proposal tailored for lunar colonization. The proposed outpost is
designed to evolve through distinct phases, utilizing four different module types: a Vertical Surface Habitat for the
living environment, two distinct Horizontal Modules serving various functions such as laboratories, storage, and
greenhouse, and an evolvable Node module that facilitates grid expansion and connection of additional modules.
Leveraging 3D modelling tools, architectural design principles, and immersive virtual reality simulations, we
consolidated our final design for the layout, structure, and interior configurations of these modules. The paper
emphasizes the importance of incorporating hybrid modules from the outset of lunar colonization efforts. This hybrid
approach, combining rigid and inflatable components, offers remarkable gains in terms of mass and volume
optimization, which are critical factors for the initial human settlement on the Moon’s surface. Through digital
evaluation systems and trade studies, we demonstrate the significance of standardization and reconfigurability of
internal usable volume within the modules. The hybrid design allows for efficient utilization of space while
accommodating the evolving needs of the colony as it grows and expands over time. This work underscores the
importance of hybrid module design for lunar colonization following the Artemis missions. Future research should
focus on further optimizing the mass of these modules through advanced materials and construction techniques, as
well as exploring additional configuration possibilities for the interiors of the horizontal modules to support a
wider range of activities. The design presented in this paper is the result of a collaborative effort with the Sasakawa
International Centre for Space Architecture (SICSA), the University of Houston, and Texas, USA. Embracing hybrid
module architecture is a crucial step towards achieving sustainable, resilient, and scalable lunar habitats, paving the
way for humanity’s permanent presence on the Moon and serving as a stepping stone for eventual crewed missions
to Mars and beyond.
Nomenclature
𝑀𝑆𝐹𝐶 = Marshall Space Flight Center
𝑆𝐼𝐶𝑆𝐴 = Sasakawa International Center for Space
Architecture
NASA = National Aeronautics and Space
Administration
mMMSEV = modified Multi-Mission Space
Exploration Vehicle
SH = Vertical Surface Habitat
𝑆𝑘𝑦f𝑙𝑜𝑤𝑒𝑟 = A transport vehicle used to shuttle
materials, modules, or supplies to/from the low lunar
orbit/surface
𝐸𝑉𝐴 = Extravehicular Activity
𝐿𝐷𝐿𝑀 = Legged Deployable Landing Mechanism
𝐸𝐶𝐿𝑆𝑆 = Environmental Control and Life Support
System
𝑚 = meters
JPL = Jet Propulsion Laboratory
𝐼𝑆𝑆 = International Space Station
𝐿𝑆𝑀𝑆 = Lunar Surface (Robotic) Manipulator
processes
𝐴𝑇𝐻𝐿𝐸𝑇𝐸 = All-Terrain Hex-Limbed Extra-
Terrestrial Explorer
𝑇𝐹𝐵 = Triple Friction Pendulum Bearing
𝐶𝑜𝑛𝑂 𝑝𝑠 = Concept of Operations
𝑋𝑅 = Extended Reality
𝑉𝑅 = Virtual Reality
1. Introduction
This paper focuses on the design of the hybrid modules
derived from a larger project outlined by Marshall
Space Flight Center (MSFC) in which the team was
tasked to design at SICSA a pathway to a sustainable
presence on the lunar south pole. The team's task is to
create a roadmap for establishing a lunar habitat. This
roadmap should address common challenges and
opportunities across different types of habitats, define
what sustainable habitation means, and identify the
characteristics that will help the habitat grow to a
75th International Astronautical Congress (IAC), Milan, Italy, 14-18 October 2024.
Copyright ©2024 by the International Astronautical Federation (IAF). All rights reserved.
IAC-24- E5.1 Page 2 of 8
sustainable state. The plan should also explore ways to
reduce the reliance on Earth for supplying the habitat
systems. The project is focused on the lunar south pole,
specifically between latitudes 84-90 degrees south, with
a maximum slope of 5 degrees. The goal is to have at
least 3 crewed launches per year with no periods of
inactivity in the habitat systems. The aim is to maintain
a continuous presence of 8 crew members, with the
capacity to accommodate a surge of 12 crew members
for up to 30 days (see Fig. 1 and Fig. 2). These plans are
based on NASA's Moon to Mars Strategy and
Objectives Development and Moon to Mars Planning
Manifest and assume that the necessary logistical and
space program capabilities are in place to support the
proposed technical assumptions [1, 2]].
Fig. 1. Possible configuration of the base in Phase 4
Fig. 2. Possible configuration of the base in Phase 4
2. Concept of Operations
The concept of operations (ConOps) focuses on both
orbital and surface activities for the successful assembly
and operation of a permanent lunar habitat. The orbital
ConOps begins with the SkyFlower conceptual lander,
which delivers habitat modules from lunar orbit to the
surface, ensuring the safe and reusable transport of
heavy cargo. This system allows refueling in orbit and
minimizes the risks associated with debris and dust
during landings. On the lunar surface, operations start
with the deployment of power systems (nuclear and
solar), rovers, and other critical infrastructure before the
arrival of the crew. Autonomous robotic systems like
the Lunar Surface Manipulator (LSMS) [3, 4] and
ATHLETE [5] rovers handle much of the heavy
construction and transportation of modules, reducing the
need for direct crew involvement during early habitat
assembly. When the crew arrives, their tasks are limited
to essential extravehicular activities (EVAs) for
monitoring and assisting in the connection of habitat
elements. These EVAs are kept to a minimum for safety
and efficiency. The habitat is designed to expand in
phases, increasing the number of modules and crew
capacity, while ensuring site independence and
operational flexibility. The ConOps also anticipates
emergency scenarios, such as radiation exposure or
structural damage, and includes contingency plans for
rapid evacuation to safe zones within the habitat or the
Lunar Gateway. The phased expansion allows for the
habitat to grow over time, accommodating more crew
members and scientific activities, with a long-term goal
of a sustainable and resilient lunar outpost [6].
3. Assets
In order to establish a sustainable, permanent base on
the moon, several key elements are necessary. These
include energy infrastructure, autonomous robotic
systems to replace manpower, suitable landing sites,
effective communications, living modules, and
transportation systems for both orbital and surface
travel. While previous research has covered the
fundamental infrastructural assets required for base
development, this paper will focus on providing a more
detailed explanation of the housing modules and the
design choices that have been made. The project
proposes four types of hybrid housing modules (Class I
and Class II) [7] with various functions, volumes,
deployments, and orientations.
These modules are the Vertical Surface Habitat (SH),
the Nodes, the Horizontal Module Type I, and the
Horizontal Module Type II.
4. Vertical Surface Habitat
The Vertical Surface Habitat serves as the central
structure of the outpost. Initially compressed for
transport, the top two floors of this habitat module
inflate to maximize interior space. This habitat contains
all essential life-support systems and can function
independently. The habitat, equipped with adjustable
landing legs, is deployed directly onto the lunar surface.
The legs, designed to elevate the habitat to a height of 4
meters, allow for connection flexibility and stability,
accommodating loads. The Vertical Habitat measures 5
meters in width and stands 11.8 meters tall when fully
deployed (see Fig. 3). This module offers access to the
lunar surface by an airlock integrated with the rigid part
of the module and one at the bottom for the connection
with the mMMSEV. The choice of the Pressurized
Rover docking from underneath changes the design of
the module drastically from studies done by NASA on
habitation modules. [8, 9, 10]
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Fig. 3. Vertical Surface Habitat (SH)
4.1 First Floor
The Class I rigid module is designed with four
interfaces: two vertical interfaces (one for connecting
with the inflatable module above and one for connecting
with the mMMSEV or Node in the next phases) and two
horizontal interfaces (one connecting the inside of the
habitat with the airlock and the other connecting the
airlock with the outside of the module). The airlock,
integrated into the module, provides two additional
interfaces for accessing the suits for EVA (2 suitports).
These interfaces are meant to minimize the transfer of
dust into the habitat. If needed, the horizontal hatch can
be used to access and enter from the airlock. The
remaining part of the module contains racks for the
ECLSS life support system, the hygiene system
(including a toilet with a dry solid waste disposal
system and a shower), and space for physical exercises
(see Fig. 4 and Fig. 5). The decision to integrate these
functions into the module is justified by the desire to
keep the noisy, dirty, and smelly areas as far away as
possible from the astronauts' private quarters located on
the third floor.
Fig. 4. Internal renders of the Floor 1
Fig. 5. Floor 1
4.2 Second Floor
This floor is the buffer between the dirtiest and most
noisy area and the crew accommodation of the habitat.
The crew uses this floor as a control room (see Fig. 6).
They can manage all the systems of the habitat, and
look at the cameras mounted in strategic positions:
vertical hatch, airlock, stairs, and additional cameras to
look around. The control room is used by two astronauts
during the EVA. The HabCom coordinates with the
Operation Team on the field performing their tasks. In
addition, the crew has control of the systems of the base
and direct communication with the Gateway and
NASA’s Mission Control.
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Fig. 6. Floor 2
4.3 Third Floor
The last floor is used by the crew outside the work
schedule of the mission. Four private spaces grant
privacy for the crew during the mission and a place
where sleep. The other part of the floor is used as a
common area/galley where the crew can eat, socialize,
read, and personalize the space (see Fig. 7 and Fig. 8).
Fig. 7. Common area/galley (Floor 3)
Fig. 8. Floor 3
4.4 Stabilizing legs
The Vertical Surface Habitat is designed to be
landed using a system that can deliver a heavy payload
from the bottom and then detach itself from the habitat.
The landing system, Skyflower, is inspired by the JPL
Skycrane landing system and will be a part of future
research. The landing legs are attached to the Cass I part
of the SH and need to be capable of absorbing the shock
during the landing phase. The design of the landing legs
takes inspiration from the Falcon 9 reusable first stage
[11]. The kinematic chain is taken from the Falcon 9's
landing legs and readapted for the SH, allowing enough
space beneath the module for the mMMSEV docking
and the future Node installation (see Fig. 9).
Fig. 9. Kinematic chain readaptation from Falcon 9 to
SH
For the other modules (Horizontals and Node), the
landing legs are not utilized during the landing phase to
absorb the shock of the landing. These modules are
lighter than the SH, so are more easily transportable by
a bigger range of landing systems.
The legs of the horizontal modules and node are
designed to be adaptable to an uneven surface and to
allow for alignment during connection. Additionally,
measures were taken to address module stability in the
event of accidental shocks, moonquakes, or vibrations
caused by module operation. A sway and vibration
dissipation system is integrated into the legs, drawing
inspiration from earthquake-resistant systems used in
Japanese foundations. This allows the foundation to
oscillate without transferring energy to the structure
above. Similarly, the stabilizing feet are designed with a
triple pendulum isolator system to reduce oscillations
[12], and the part of the foot in contact with the surface
is anchored with the deeper layers of regolith for
stability (see Fig. 10).
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Fig. 10. Triple friction pendulum isolators (TFB)
4.5 Vertical Docking with mMMSEV
As previously mentioned, the Vertical Surface
Habitat is designed to be elevated from the ground by 4
meters. This feature offers the capability to dock the
pressurized rover beneath the habitat during the first
phase (see Fig. 11).
Fig. 11. mMMSEV docked with the SH
The modified pressurized rover with an additional
docking interface on top, known as the mMMSEV, will
be loaded with furniture, consumables, and other cargo
for the habitat before the astronauts arrive. The rover
will autonomously drive from the designated landing
area for cargo to the habitat. Upon docking at the
bottom of the habitat, it will unload all the necessary
cargo for the first crew of astronauts.
Docking the pressurized rover from the bottom
provides additional storage space for the first crew of
four astronauts (see Fig. 12).
In the later phases of) development, the pressurized
rover will be moved from the bottom of the habitat to
dock with one or more horizontal modules, as shown in
Fig. 1 and Fig. 2.
Fig. 12. Section of Surface Vertical Habitat and the
mMMSEV docked
5. Nodes
The Node module acts as a critical connecting hub
within the outpost, attaching beneath the Vertical
Surface Habitat and providing two expansion directions.
This module enables flexible branching to the
Horizontal Type 1 and Type 2 modules at angles of 90,
120, or 180 degrees, offering versatile layout options
(see Fig. 13).
Fig. 13. Nodes: 180° - 120° - 90°
Measuring 3 meters in width, the Node also serves as a
primary radiation shelter for the outpost. Each Node can
accommodate up to four crewmembers, enhancing the
safety and resilience of the habitat. An additional layer
of enriched hydrogen material for radiation protection
[13] (see Fig. 14).
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Fig. 14. The radiation shell grants protection during
solar flares or particle events
6. Horizontal Modules
The outpost features two types of horizontal habitats:
Type 1 and Type 2. Both modules have an undeployed
diameter of 3 meters to fit various launch fairings. The
Type 1 module is designed to be slimmer and more
modular, with an undeployed length of 5 meters that
extends to 10 meters when deployed. The Type 2
module is broader, measuring 7 meters in both length
and width. This phase allows the pressurized rover to
dock with either of the horizontal modules. The interior
of these modules is characterized by a movable rack
system designed for a better utilization of the available
volume. This system contains embedded rails that allow
the racks to slide along the length of the module and
free areas to work in as needed. This system offers a
more adaptable usage of space and access from multiple
angles, benefiting tasks such as plant care and stowage.
6.1 Horizontal Module Type 1
The Horizontal Type 1 module is added to connect
additional clusters for base expansion. More Vertical
Surface Habitats will arrive, allowing the base to
accommodate more crews at once (one cluster per SH).
Inspired by research done by ILC Dover on expanding
hybrid modules longitudinally [14], the module is
designed to be transported to the Moon in a compact,
folded configuration. Deployment and pressurization
will occur only during installation and connection to the
base. Before deployment, the module is 5 meters long
and will reach 10 meters when deployed linearly. The
width of the module is limited to 3 meters, presenting
several difficulties in the internal organization of space.
Multiple virtual reality tests were conducted to improve
the module design in an iterative process [15].
Fig. 15. Movable rack system inside the Horiz. Type I
A system of racks mounted on rails that expand
along the length of the module was chosen, taking
inspiration from the system studied by the project in
collaboration with ESA FlexHab [16]. The organization
of space with movable racks allows for flexible
distribution of functions that can be shared by the two
clusters that the module connects. The movable racks
can create niches or be compacted to create larger
spaces according to the crew's needs (see Fig. 15) [17].
Fig. 16. Horizontal Module Type I
6.2 Horizontal Module Type 2
The Horizontal Type 2 module is similarly added to
the base to initiate expansion and further the outposts
capacities. This module has an undeployed length of 7
meters and an undeployed diameter of 3 meters.
Similarly to the Horizontal Type 1 module, the
Horizontal Type 2 module is landed and transported to
the base in its undeployed state. Once docking has
successfully occurred, this module expands laterally to a
width of 7 meters (see Fig. 16). While the Horizontal
Type 1 module offers a more compact and narrower
workspace suitable for smaller science experiments, the
Type 2 module has a lot more workable space. This
allows for larger partial gravity research experiments
and sample analysis.
Due to the non-linear nature of the expansion of this
module, the internal floor space is ovular in shape. This
complicates the adaptation of the horizontal sliding
racks of the Type 1 module. Instead, pre-defined block
spaces measuring 1.1 meters in width are used in this
module, allowing for flexible interchanging and
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relocation of the furniture and equipment in this
module.
Fig. 17. Horizontal Module Type II
7. Evaluation Methodology
The design methodology used is iterative. The use of
virtual reality has been part of the design process as a
tool for validating design choices, as explained before.
An incremental level of immersiveness with XR allows
for increasingly detailed and complex iterations,
accompanying the designer during design choices [14].
The evaluation framework used is consistent with the
research done at SICSA in collaboration with Boeing in
the last few years.
6. Conclusions
There are several areas of the outpost that could use
additional time in research and shortcomings that could
be addressed. This project didn’t cover trade-study
depth on the costs and feasibility of each mission, and
whether each phase of the outpost evolution could be
largest component of the habitat – the Type 1 vertical
habitat, is limited in space when factoring in life support
systems, crew complements, stowage, and consumables.
While the Phase 1 stage of the outpost allows for human
presence on the lunar surface, the length of mission
duration is limited without expansion for additional
consumables and supply stowage. Having a highly
desired (but not required) expansion plan could make
long-term mission success a risk if a program or
customer implements cuts or withdrawal from
additional expansion plans. In terms of habitability, the
addition of human-centered creature comforts were
feedback items the team had considered. Even the
proposal of portholes in the primary/Vertical Surface
Habitat could have a positive impact on crew
psychological support, in addition to greater situational
awareness of the outpost’s exterior. Further, this project
did not allow for time to elaborate on customization,
soundproofing, or better separation of crew quarters in
the vertical habitat. The current design and rendering of
the project have relatively thin barriers depicted in the
crew quarters area, which could lead to a less
personable and noisier feeling to the crew’s personal
space. Finally, at this preliminary stage of the project,
the thermal management of the modules has been
neglected, and the mass estimation of the modules is not
refined and can be analyzed more accurately.
Acknowledgments
The authors would first like to acknowledge and thank
Paul Kessler and James Johnson of the Habitation
Systems Development Office at Marshall Space Flight
Center for dedicating their time to tasking and
evaluating SICSA students with this challenging project.
In addition, we would like to thank our dedicated
instructors and assistants for their continual helpful
nudging of our project in the right direction; Larry
Toups, Larry Bell, and Vittorio Netti.
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