ACRE project diagram and technical details
Figure: ACRE rover concept showing solar concentrator, regolith hopper, and casting stages (from the technical paper).

Drawing from the ACRE technical paper submitted to NASA's BIG Idea "Lunar Forge" challenge, this project demonstrates solar-thermal ISRU for casting lunar regolith into structural elements. The rover integrates heliostat-directed collection, thermal storage, and mold handling to autonomously print and deploy pavers.

Paper takeaways

  • Solar concentration and thermal storage maintain melt temperatures for regolith casting without consumables.
  • Closed-loop sensing coordinates hopper feed, mold filling, and controlled cooling to reduce cracking.
  • Mechanical tests on cast coupons show strengths suitable for landing pad paving and load distribution.

Results that matter

  • Prototype rover completed end-to-end casting cycles with field-collected regolith simulant.
  • Thermal modeling and lab trials validated heat budgets for repeated pours under lunar day conditions.
  • System architecture earned a top NASA BIG Idea award for manufacturability and mission impact.