Design and Optimization of a Self-Expanding Lunar Factory: System Architecture and Resource Utilization Modeling

Abstract

This thesis presents the design and modeling of a self-expanding lunar factory capable of utilizing resources on the Moon to manufacture components for its own growth. A comprehensive system architecture is developed integrating extraction, processing, manufacturing, and assembly subsystems optimized for the lunar environment, with a focus on achieving high resource closure rates while remaining feasible with near-term technologies. An 8,925 kg initial factory configuration is established for further analysis. A time-step simulation model is implemented to evaluate factory growth dynamics, resource utilization efficiency, and production bottlenecks under various operational scenarios. Using a genetic algorithm to optimize resource allocation strategies, the model demonstrates the initial factory can triple its mass over five years of operation, with 85% of new components manufactured from lunar resources. Key findings reveal that power constraints and processing bottlenecks significantly impact growth trajectories, producing linear rather than exponential growth. Counterintuitively, increased Earth resupply (2,500 kg/yr vs. 500 kg/yr) resulted in not only greater total mass growth (44,491 kg vs. 25,318 kg) but also a higher percentage of lunar-sourced components (71.3% vs. 57.9%). This work provides insights into production process integration, operational constraints, and growth potential of self-expanding lunar manufacturing, demonstrating how strategic design choices can help establish sustainable industrial capability on the Moon with minimal Earth dependence.