New Mars Forums
You are not logged in.
- Topics: Active | Unanswered
Announcement
#51 2026-02-16 09:51:44
- SpaceNut
- Administrator
- From: New Hampshire
- Registered: 2004-07-22
- Posts: 30,520
Re: Ring Habitat on Mars Doughnut Torus
surprise we are still in the same range for material mass whether its the 304L or the Austenitic High-Manganese Steel: roughly 1,000 tons for the same tubing dimensions
Offline
Like button can go here
#52 2026-02-16 16:34:19
- kbd512
- Administrator
- Registered: 2015-01-02
- Posts: 8,506
Re: Ring Habitat on Mars Doughnut Torus
SpaceNut,
Was there any mass reduction at all?
Online
Like button can go here
#53 2026-02-16 19:09:43
- SpaceNut
- Administrator
- From: New Hampshire
- Registered: 2004-07-22
- Posts: 30,520
Re: Ring Habitat on Mars Doughnut Torus
There may have been a bit but not any thing that mattered.
I am going to think of another plan to build with the fabric, and regolith but targeting just 100 so that it can be repeated as many times as we need. Once its got air in it and not losing it we may be able to do counter pressure with more materials on the out side with more fabric and regolith. Interlocking the tiers for a finished shape.
I will create a new topic later
Offline
Like button can go here
#54 2026-02-16 20:13:18
- kbd512
- Administrator
- Registered: 2015-01-02
- Posts: 8,506
Re: Ring Habitat on Mars Doughnut Torus
SpaceNut,
Maybe we are better off using impermeable fabric and regolith bags only. There's no significant upper limit to the size of inflatable structures here on Earth.
Take note of the size of the human standing to the left of this structure:
Look at how tiny the cranes are next to this inflatable:
If we can pressurize and fill with regolith dust for structural support and radiation protection, then the habitat should still be there a century from now. That ought to provide sufficient time for Iron mining and smelting for steel construction.
Online
Like button can go here
#55 2026-02-17 15:21:41
- SpaceNut
- Administrator
- From: New Hampshire
- Registered: 2004-07-22
- Posts: 30,520
Re: Ring Habitat on Mars Doughnut Torus
I went back in on a clean sheet and organized the Hesco wall thickness and height for the dome exoskeleton to fit around leaving it to tell me the tubing OD and thickness. When its doing dead mass support for the regolith shield. Its response was 100mm OD at 5mm wall thickness.
Since the lengths are fresh and not long enough for the cross members that means we are welding butt to butt, bending and then cutting for full length. This means waste materials not useable of the order of 10-15% for use even for making each piece count.
The mass for the exoskeleton for the Austenitic High-Manganese Steel: comes in over 890mT.
Of course the dual 30mm OD that is 4mm thick is recycled so there is no waste and the amount of lengths can be made without butt welds.
which came in at a bit less coming in at 860 mT.
The issue for both is the mass of the regolith that does not distribute the load into the Hesco barrier wall as the bags are not changing shape of compressed amounts with in them such that they shift and slide and are not like a solid wall.
I looked at wrapping like a woven basket in and around the bags which it helps to keep things less drifty.
Looked at no dome but using a framing for the vertran fabric to form the inflatable using the impregnated to form the inflatable with each layer of the Hesco barrier wall having its mass pushing down on its as it wraps around each course to provide the tension. Building each layer of bags continuing to do the same as the wall rises.
Then once its inflated we begin to build concentric rings of regolith with the woven strip holding as before that was used in the wall. It keeps the mass of the regolith load shifting to the wall and not the inflatable under it.
I also looked at how to make the regolith more solid plus bagged shape. It requires us to mix the low temperature binder and mix it with the regolith compacting the contents of the bag before heating within the shape mold that continues to compress while it heats. The you allow it to cool before moving.
The thermoplastics powder was used as the binder which was mixed in in ratio of for building a 30 m diameter dome. The percentage from 10% - 15% means bringing 10 mt to 30 mT that melt at in the 80'C to 130'C. This makes for a better build as we go.
Offline
Like button can go here
#56 Yesterday 17:52:38
- SpaceNut
- Administrator
- From: New Hampshire
- Registered: 2004-07-22
- Posts: 30,520
Re: Ring Habitat on Mars Doughnut Torus
brought from earth types
You can bring several Earth‑manufactured thermoplastic powders to Mars, and they fall into a few well‑defined families. These are all commercially available, stable in storage, and compatible with compression molding, sintering, or melt‑fusion processes you’d use for regolith‑plastic composite tiles. The categories below reflect the major industrial types used today, along with their properties and relevance to Mars operations.
? Major thermoplastic powders you can ship from Earth
These are the standard industrial powders used for coatings, molding, and sintering. They melt and re‑solidify without chemical curing, making them ideal for repeated heating cycles.
? Polyethylene (LDPE, HDPE)
Low melting point (105–135°C).
Excellent chemical resistance and toughness.
Common in powder‑coating applications.
LDPE and HDPE are both widely available as powder feedstock.
Identified as a major thermoplastic powder type in industrial catalogs.
? Polypropylene (PP)
Slightly higher melting point (150–165°C).
Good stiffness‑to‑weight ratio.
Very stable under UV when additives are included.
Often used in fluidized‑bed powder coatings.
? Nylon (Polyamide 11, 12)
High abrasion resistance.
Good for mechanical parts, hinges, wear surfaces.
Melts around 180–190°C.
Used in industrial powder coatings for durability.
? PVC (polyvinyl chloride) powder
Used in thick, protective coatings.
Good for corrosion‑resistant layers.
Requires careful temperature control to avoid decomposition.
? EVA (ethylene‑vinyl acetate)
Very low melting point.
Flexible and impact‑absorbing.
Useful as a binder for regolith composite tiles.
? Specialty thermoplastic powders
These are engineered for industrial coating systems and can be shipped in drums.
? HAPA (High Adhesion Polymer Alloy)
Designed for strong bonding to metal substrates.
Listed as a commercial thermoplastic powder type.
? Plascoat® family (PE‑based)
Used for corrosion protection, playground equipment, and harsh environments.
A major commercial thermoplastic powder line.
These are attractive for Mars because they are already optimized for durability, adhesion, and environmental resistance.
? Thermoplastic vs. thermoset powders (important distinction)
Thermoplastic powders:
Melt when heated and can be re‑melted.
Used in fluidized‑bed and fusion‑bonded coatings.
Provide chemical resistance and durability.
Industrial sources emphasize their reusability and melt‑flow behavior.
Thermoset powders:
Cure chemically and cannot be re‑melted.
Not suitable for your tile‑molding system because they cannot be reprocessed.
? Best choices to bring to Mars for your tile‑production system
For your regolith‑plastic composite tile workflow, the most practical Earth‑supplied powders are:
1. LDPE or HDPE powder
Lowest energy requirement for melting.
Extremely stable in storage.
Compatible with compression molding and sintering.
2. PP powder
Higher stiffness than PE.
Good for structural tiles.
3. Nylon 11/12 powder
Best for high‑wear components.
Useful for mechanical interfaces, hinges, and abrasion‑resistant surfaces.
4. EVA powder
Excellent binder for regolith composites.
Low melt temperature reduces power load.
? How to choose which to ship
A simple decision rule:
Requirement Best Powder
Lowest melt energy LDPE / EVA
Highest toughness HDPE
Highest stiffness PP
Wear resistance Nylon 11/12
Best adhesion HAPA / Plascoat®
If you want, I can size the mass budget for bringing each powder type from Earth based on your tile production rate and the regolith‑to‑binder ratio you plan to use.
Offline
Like button can go here