SPACE (Solidified Profile Aluminum Cast Extrusions)

The SPACE (Solidified Profile Aluminum Cast Extrusions) technology is a materials and manufacturing approach that comprised of additive free form casting and high strength aluminum alloy that enable lunar infrastructure construction by the free form casting of structural components such as truss members, angles, rods, and tubes from molten aluminum and other ISRU-derived metals. Merging the efficiency of Direct Chill (DC) casting with the precision of tube extrusion techniques, SPACE optimally utilizes ISRU-derived materials, casting them into complex shapes while leveraging latent heat of solidification (~420 kJ/Kg Al) to boost process energy efficiency. Furthermore, SPACE employs specially designed nozzles to capture and repurpose waste heat generated during solidification, using this recovered energy to power accumulators for molten material extrusion and normalizing heat-treatment. This approach not only enhances the system's energy efficiency but also significantly reduces reliance on Earth-sourced consumables and manufacturing equipment, making it an ideal solution for producing durable materials from aluminum and aluminum-scandium alloys. Designed to support Artemis missions and sustainable lunar colonization efforts, SPACE technology facilitates the construction of lunar infrastructure, promoting the sustainable use of in-situ resources.