New Mars Forums

Trying to do without prefilling of numbers being generated making use of excel and auto fill to do my best

starting post is carried from the previous days 3-07-2026 last number for the day 238433 - last post 238442

3-8-26 postings

Bipolar Mars Terraform Plan

Martian Calender - I have created a martian calender...

Google Meet Collaboration - Meetings Plus Followup Discussion
Google Meet Collaboration - Meetings Plus Followup Discussion
Google Meet Collaboration - Meetings Plus Followup Discussion

Why Artemis is “better” than Apollo.

Mars Direct 3 is a Mars mission architecture developed by Miguel Gurre
Daily Recap - Recapitulation of Posts in NewMars by Day
Daily Recap - Recapitulation of Posts in NewMars by Day

Mars Direct 3 is a Mars mission architecture developed by Miguel Gurre

Fixing the boiloff means adding mass and power requirements to perform the task.

An important step even for starship current systems.

thanks for the reminder as the computer is not on a network to do automatic update.

NASA must delay deorbiting the ISS, U.S. lawmakers say

U.S. lawmakers are moving to delay the International Space Station’s retirement, giving more time for commercial replacements to be built
Meghan Bartels
Fri, March 6, 2026 at 1:37 PM EST

"Shopping List for Mars Construction Testbed"

1. Regolith Simulant Ingredients

• Traction sand / construction sand (angular)

• Black Diamond blasting sand (basaltic fines)

• Stone dust / crusher fines

• Red iron oxide pigment

• Optional: gypsum powder

2. Sifting & Grain-Size Control

• Sieve set: 1 mm, 500 µm, 250 µm, 125 µm, 63 µm

• Hand or electric sieve shaker

• Plastic/metal collection bins

3. Thermal Processing Equipment

• Drying oven (100–150°C)

• Shallow metal trays (2–3 cm depth)

• Thermocouples / digital temperature probes

• Heat-resistant gloves

• Cooling racks

4. Cold-Weather / Heated-Tent Environment

• Heated work tent or insulated shelter

• Portable electric heater (1–2 kW)

• Thermal blankets or foam insulation panels

• Cold-weather PPE

5. Construction & Binder Materials

• Epoxy resin kits

• Sodium silicate (waterglass)

• Sulfur binder (pellets or powder)

• Geopolymer binder

• Thermoplastics: PLA, ABS, Nylon

• Fibers: glass, basalt, polymer

• Plasticizers and hardeners

6. Molding & 3D Printing Tools

• Casting molds (tiles, bricks, beams, panels)

• 3D printer (standard or modified for regolith extrusion)

• Mixing bowls, spatulas, measuring cups

• Digital scale (0.1 g resolution)

• Optional: vibration table

7. Measurement & Testing Tools

• Compression tester (manual or hydraulic)

• Bulk density cylinder

• Moisture meter

• Digital calipers

• Notebook or digital logbook

8. Optional: Full Mars Workflow Simulation

• Pea gravel (4–8 mm)

• 3/8" crushed stone

• Extra stone dust

• Small rock crusher (for gravel → sand processing)

For 1 cubic meter of Mars‑sand analog:

60% angular construction sand

25% basaltic fines (Black Diamond blasting sand)

10% stone dust / crusher fines

3% red iron oxide

2% gypsum (optional)

This produces a 63 µm – 1 mm grain band after sieving.

This is the material you’ll use for:

Molds

3D printing

Binders

Adhesives

Tiles

Bricks

Panels

Structural elements

And because you’re using heated tents and cold ambient conditions, your Earth results = Mars results.

How to play mars insitu on earth as the same for Mars, not finely processed as the simulants have done so far on earth.
This uses the same processing unit that starts for water from regolith but now uses the together mars ready course sand grain materials.
This is what is the same point on earth that cohesively makes mars on earth with the same rules.

Building Mars‑Ready Construction Methods on Earth Using a Unified Regolith Workflow**

Over the past several months I’ve been developing a practical, end‑to‑end method for designing and testing Mars construction techniques on Earth. The goal is simple:

Use the same starting material state, the same temperature controls, and the same process steps on Earth that we would use on Mars — so every experiment directly transfers.

Below is the full workflow, broken down so others can follow, critique, and build on it.

1. Why Start With the Same Material State?
On Mars, a scoop of raw regolith contains:

Dust

Sand

Gravel

Larger rocks

After processing, only the sand fraction (63 µm – 1 mm) becomes the primary feedstock for construction, 3D printing, molding, and binder experiments.

Typical assumed distribution per cubic meter of raw regolith:

20% dust

50% sand

30% gravel

This means:

To get 1 m³ of usable sand on Mars, you must process 2 m³ of raw regolith.

On Earth, we skip the upstream waste and directly prepare 1 m³ of Mars‑like sand as the standard starting point.

2. Earth Equivalent: Creating the Final Mars‑Sand Product
To match the post‑processed Mars sand, I prepare a mixture with:

Angular construction/traction sand

Basaltic fines or Black Diamond blasting sand

A small amount of stone dust

A touch of red iron oxide for color and chemistry

Then I sieve to keep only the 63 µm – 1 mm fraction.
This becomes the canonical Earth starting material for all construction tests.

3. Mars Thermal Processing → Earth Thermal Processing
Mars:
A 10 kWe fission surface power unit produces ~30 kW of thermal waste heat.

That waste heat drives a moving‑tray “pizza oven” reactor.

Regolith is baked to remove water and volatiles.

Baked sand exits as the construction feedstock.

Earth:
I use a drying oven to match the same temperature window and tray depth.

Same cycle times, same thermal behavior, same handling.

This ensures thermal results (binder curing, moisture removal, sintering behavior) match Mars conditions.

4. Mechanical Chain (Mars vs. Earth)
Mars System

• [] Telerobotic battery‑powered bulldozer
  [] Track‑scoop head lifts regolith
  [] Auger removes large rocks
  [] Fine fraction enters heated tray reactor
  [] Water is collected for fuel or life support
  [] Baked sand is stored for construction

Earth System

• [] Load prepared Mars‑sand simulant
  [] Dry in oven to match Mars thermal profile
  [] Sift if needed to maintain grain band
  [] Use in molds, 3D printing, binders, adhesives, plastics, etc.

The workflows are intentionally parallel.

5. Why This Makes Earth Tests Directly Transferable to Mars
Because I match:

• [] Material state (post‑processed sand fraction)
  [] Temperature controls (cold ambient + heated tent/enclosure)
  [] Process steps (tray heating, sifting, mixing, molding)
  [] Operational constraints (limited power, batch cycles, abrasive material)

…any binder, adhesive, plastic, mold, or 3D printing technique I test on Earth behaves the same way on Mars.

This includes:

Cure times

Flow behavior

Strength

Shrinkage

Layer adhesion

Thermal response

The only major differences left are gravity and atmospheric pressure, which can be tested separately if needed.

6. Engineering Metrics Gained From Earth Testing
By running the full workflow on Earth, I now know:

• [] Power per batch
  [] Power per cubic meter of sand
  [] Man‑hours / robot‑hours per cycle
  [] Throughput per sol
  [] Thermal cycle times
  [] Handling and loading times

• Wear points and maintenance intervals

These are the numbers mission planners and ISRU designers need — and they come from real operations, not theory.

7. Why I’m Sharing This
This approach gives us a repeatable, Mars‑faithful method for testing:

Regolith construction

Binders and composites

3D printing

Molded blocks and panels

Thermal processing

Robotic workflows

Power budgeting

Habitat fabrication techniques

Anyone can reproduce this workflow on Earth with simple equipment and a consistent simulant.

I’m sharing it so others can:

Build their own rigs

Test their own binders

Validate their own construction ideas

Compare results using the same starting point

If we all use the same 1 m³ Mars‑sand standard, our results become comparable and cumulative.

well I ran the pdf through copilot to get info.

Since starship even as cargo payload can not bring LCH4 due to boiloff with no active cooling system and is not large enough to carry the methane as gaseous either.

Shipping water would be better as it does not boiloff....

sent out follow up emails as to the issue for the web masters

Much of this was based on Starship and that due to many things it should be converted to a 2 stage booster to put more reasonable payloads into orbit that can do work without refueling...

We have been basing on Mars edl that Nasa wanted years ago.
Forty 40 Ton Mars Delivery Mechanism

This creates a 100 mT payload rocket to ride as a modified starship 2nd stage booster which would accommodate a series of ships all capable of going to the more and modified for the moon as well.

With most pieces being reusable with more capability at less refueling amounts.

First we are in need of a man rated delivery and return from LEO. This is a transfer ship of crew and modular canister payload system.
second is an ERV that transit to mars carrying the crew to awaiting transfer point in orbit for a MAV for Mars that is waiting in Mars orbit.
Third ship carries the Crew and for Cargo to the Mars landing site. To which once the cargo is off loaded it can be refueled and sent to orbit to bring back down more cargo if any is waiting.

its been reported...

composite materials topic wiki has been updated

For a pressurized habitat you need high specific strength, tensile capacity, and controlled failure modes—that's real structural composites territory.
Let's talk about a system that actually fits that brief.
1.    What a pressurized composite shell really needs
For a habitat at roughly Earth-like pressure:
    High tensile strength: The shell is mostly in hoop tension; compressive-only materials (concretes, geopolymers) are not enough on their own.
    High specific strength: You want light skins that carry pressure, not meter-thick heavy walls.
    Leak-tight and damage-tolerant: Multiple layers, controlled crack paths, repairable.
That points to fiber-reinforced polymer skins plus a lightweight core—a classic sandwich composite—backed up by regolith for radiation and micrometeoroid shielding.
2.    Architecture that actually works on Mars
2.1 Separate the jobs
1    . Inner pressure shell:
o Thin, strong, lightweight composite. o Carries the pressure load.
2    Outer shield:
D Regolith berm or blocks.
o Provides radiation and impact protection, thermal inertia.
3.    Structural frame (optional):
c Rings, ribs, or a lattice that the composite panels attach to. o Can be metal or composite.
This way, the composite mass stays low, and regolith does the "heavy" job where weight is tine.
3.    Realistic composite materials under your constraints
3.1    Skins: high-performance fibers + low-temp resin You basically have two options:
1    . Import both fibers and resin (early phase):
  Fibers: Carbon or aramid (Kevlar-class).
  Resin: Epoxy or toughened thermoset that cures at <80 cc.
  Pros: Lowest risk, lowest process temperature, minimal equipment.    Cons: You're importing all the high-value material.
2    Import resin, make fibers on Mars (mid-term):
  Fibers: Basalt-like or glass fibers from regolith.
  Heat source: Solar concentrators for melting (N I 400-1500 oc), so electrical power stays low even though temperature is high. 
  Resin: Still imported, low-temp cure.
  Pros: Big reduction in imported mass (fibers are the bulk of the skin mass).
  Cons: More complex equipment; you accept high temperature but not high electrical power.
Either way, the curing temperature of the composite can stay in the 50-80 o c range.
3.2    Core: regolith-based, low-temp, lightweight
The core doesn't need huge tensile strength; it needs shear stiffness and buclding resistance:
    Option A: Regolith-geopolymer foam or honeycomb o Make a thin-walled lattice or honeycomb from geopolymerized regolith at
<80-1 oo oc.
    Low density, good shear stiffness.
    Option B: 3D-printed regolith lattice c Print an open-cell lattice (trusses, octet, etc.) using a low-temp binder      (geopolymer, phosphate cement, or polymer). c Skins bond to this lattice.
    Option C: Imported polymer foam (early phase) c Very low mass, easy to process, but imported.
The core is where real Mars regolith can shine without needing to be high-tensile.
4.    Equipment set for lightweight structural composites
4.1 For skins
    Fiber supply:
    Early: spools of carbon/aramid fiber from Earth.
    Later: solar furnace + fiber drawing Line for basalt/glass fibers from regolith (thermal, not electric).
    Layup and curing:
  Equipment:
    Simple layup tables or mandrels (for curved panels).
    Rollers, vacuum bagging gear.
    Low-temperature curing oven or heated tent (50—80 o c).
  Electrical power:
    Pumps, controls, and heaters: typically 10-30 kWh per ton of cured composite.
4.2 For cores
    Regolith processing:
  Excavation, screening, milling (if needed): 20—50 kWh/ton of core material.   Binder handling (geopolymer/phosphate):
    Mixers, dosing pumps, low-temp curing chamber: 5-20kWh/ton.      Forming:
0 3D printer or molds for honeycomb/lattice.
a Drives and actuators: a few kWh per cubic rneter of core.
4.3 Assembly
    Panel bonding:
    Adhesive bonding or co-curing skins to core. o Low-temp cure again (<80 0C).   Integration into habitat:
    Mechanical fasteners or bonded joints to rings/ribs. o Sealant layers and inner liners for leak-tightness.
5.    Power and mass picture for a habitat shell
Let's sketch a ballpark for a small cylindrical habitat:
    Habitat: 4 m diameter, 10 m long, 1 bar internal pressure.   Composite shell:
c Sandwich panels with N2—3 mm skins and N50-100 mm core.
o    Total composite mass maybe on the order of 5—10 tons (depends on design). Electrical energy to fabricate (order of magnitude):   Skins:
a Layup + curing: say 20—40 kWh/ton + 100—400 kWh total.   Cores (regolith-based):
o    Regolith processing + forming + curing: 40-80 kWh/ton 200-800 kWh. So you're in the rough range of 300—1200 kWh of electrical energy to fabricate the shell, spread over weeks—well within a tens-of-kW power system.
The high-temperature part (if you make fibers locally) is driven by solar thermal, not electrical, so it doesn't blow your power budget.
6.    Why this meets your criteria   Structural composite:
o    True fiber-reinforced skins + engineered core high specific strength, sujtab[e for pressure shells.   Light in mass:
o    Thin skins, low-density core, regolith only where it doesn't hurt (shielding, not pressure).
o    Usable for pressurized habitats:
o    You're essentially building aerospace-style composite pressure shells, just with regolith-derived cores and possibly fibers. • Low electrical power and low temperature:
o    All chemistry and curing kept below N80—100 o c.
c High-temperature melting (if used) offloaded to solar concentrators. If you want to go deeper, we can pick one concrete configuration—say imported carbon fiber + regolith lattice core + 50 kW peak electrical cap—and walk through a more detailed mass and panel-by-panel design.
does mars temperatures support chemistry and curing kept below N80—a 00 o c
Mars absolutely can support composite chemistries that cure below 80—100 oc, but only if you design the process around the planet's thermal environment rather than trying to use ambient conditions alone. The key is understanding what Mars does provide, what it doesn't, and how to bridge the gap with low-power equipment.
What Mars actually gives you thermally
Mars is cold—very cold. Typical Surface temperatures range from about 20 o c at midday near the equator down to —100 oc or Lower at night, with an average around —62 c c.
That means:
    Ambient Mars temperatures are far below any composite curing temperature, even "low-temp" resins that cure at 40—80 oc.
    You cannot rely on the environment to provide cu ring heat.
    You can rely on the environment to provide excellent heat sinks for cooling and for stabilizing temperature gradients once curing is done.
So the question becomes: Can we heat composite parts to 40—80 oc with low power? The answer is yes—because the mass of the composite shell is small, and the insulation requirements are modest.
Why low-temperature curing is still feasible on Mars
Even though Mars is cold, heating a composite panel to 60-80 oc is a small, localized, low-power task. You're not heating a building—you're heating a thin laminate or a sandwich panel.
Typical composite curing energy
For a 2—3 mm composite skin panel:
    Mass: ru5—10 kg/m2
    Heat needed to raise resin + fiber to 80 oc: NO.2—0.4 kWh/m2   Curing oven losses (with insulation): NO. 1—0.3 kWh/m2
So curing a 10 rn2 panel might take only 3—7 kWh of electrical energy.
This is well within the capability of a 10—20 kW power system, even if you cure multiple panels per day.
How to achieve 40—80 oc curing on Mars with low power
1. Insulated curing tents or small ovens
    Lightweight aerogel or multilayer insulation.
    Electric resistance heaters or heat pumps.
    Very small volume very low power draw.
2.    Solar thermal assist
Even though Mars is cold, sunlight is still strong enough for:
    Black-body absorption tents (greenhouse-like curing enclosures).
    Solar concentrators to preheat air or thermal mass.
This can reduce electrical power by 50—80%.
3. Localized heating
Instead of heating the whole panel:
    Use heated molds, heated platens, or resistive heating blankets.   Only the composite itself reaches curing temperature.
This is how many low-temp aerospace composites are cured on Earth.    
Which composite chemistries work below 80—100 oc? These are all compatible with Mars:   Low-temperature epoxies   Cure at 40-80 oc.
    High strength, excellent for pressure shells.
    Imported resin mass is small (tens to hundreds of kg).
  Toughened thermoplastics (low-melt)      Some soften and bond at 70—120 oc.
    Recyclable and repairable.
  Polyurethane or polyurea systems
    Cure at ambient to 60 oc.
    Good toughness and crack resistance.
  Bio-derived polymers (mid-term)
    Chitosan, starch-based, or lignin-based binders.
    Cure at ambient to 80 DC.
    Can be produced from life-support waste streams.
All of these are compatible with Mars's thermal environment as long as you provide a small heated enclosure.
  Why this is enough for pressurized composite habitats A pressurized habitat shell is thin:
    2—4 mm composite skins
    50—100 mm lightweight core
    Total pane( thickness: 5—10 cm
    Total mass: a few tons
Heating a few tons of material to 60—80 oc over several days is trivial for a Mars base with even 10—20 kW of electrical power.
The cold environment actually helps once curing is done:
    Composite strength increases at low temperature.
    Thermal contraction can be managed with proper design.
    The outer regolith berm provides thermal stability.
The real limitation isn't temperature—it's binder and fiber supply
Mars's cold climate doesn't stop composite curing. The real constraints are:
    Resin availability (imported or ISRU-produced).
    Fiber availability (imported carbon/aramid vs. solar-made basalt).   Panel manufacturing throughput.
Temperature is the easiest part of the problem.
If you want, I can map out a full low-power curing system sized for a specific habitat (e.g., 4 m x 10 m cylinder) and show the exact kWh/day needed.
1.    Example habitat and shell
Let's pick something modest but realistic:
    Habitat: Cylinder, 4 m diameter, 10 m long
    Internal pressure: NI bar
    Composite shell: Sandwich panels o Skins: mm fiber-reinforced polymer o Core: N70 mm lightweight regolith-based lattice/foam c Total panel thickness: •v8 cm
Surface area of the cylinder + two endcaps is roughly 125 m 2 . Assume we build this from 10 m2 panels + about 13 panels.
2.    Heating and curing one panel Take a 10 m2 panel:
         Skin mass: N7 kg/m2 x 10 rn2 70 kg
  Core mass: say 20 kg/m2 x 10 m 2 200 kg
• Total panel mass: Q70 kg
To heat that from, say, 0 oc to 70 oc:
    Energy z 0.07 kWh per 10 kg per 70 oc + —1.3—1.5 kWh into the material   Add oven/tent losses and inefficiencies -•3—5 kWh per panel is a reasonable target so:
    Per 10 m2 panel: N3—5 kWh to cure
    AIL 13 panels: N40—65 kWh total curing energy
That's electrical energy, not counting any solar thermal assist.
3.    What the curing hardware Looks Like Curing enclosure:
    Type: Insulated tent or small oven that fits one 10 m2 panel at a time
    Insulation: Multilayer foil + foam/aerogel panels   Heat source:
    Electric resistance heaters or heat mats c Optional: solar-heated air loop to pre-warm the enclosure Power draw:
    Suppose the heaters are rated at 2 kW.
    To deliver 4 kWh to a panel, you run them for about 2 hours (plus some soak time).
    You can easily do 2—3 panels per sol on a 10—20 kW base, even with other loads.
4.    Total curing load for the shell
If we take the mid-range 5 kWh per panel:
    13 panels x 5 kWh z 65 kWh total curing energy Spread over, say, 7 sols:
    -9-10 kWh/s01 average
    With a 10 kW power slice, that's less than 1 hour of full-power curing per sol, or longer at lower power.
So from a power-system perspective, curing the entire composite shell is a small, schedulable toad, not a dominant one.
5.    How Mars temperatures fit into this      Outside, it might be —60 oc.
•    Inside the curing tent, you hold 70 DC.
•    Good insulation keeps the heater duty cycle low.
•    After curing, you can let the panel cool toward ambient or toward a controlled intermediate temperature before installation.    
The cold environment is a challenge for holding temperature, but because each panel is relatively light and the enclosure is small, the absolute energy required stays low. If you'd like, next step could be: pick materials (e.g., imported carbon fiber + low-temp epoxy + regolith lattice core) and we can rough out how many kg of Earth-supplied stuff you'd actually need for that 4 m x 10 m habitat.