Proof of Concept

This plot illustrates the difference in moisture absorption rates for nylon on Earth versus Mars. Due to Earth’s humid atmosphere, nylon rapidly absorbs moisture, leading to increased mass and reduced mechanical performance. A major challenge for 3D printing. In contrast, Mars’ extremely dry environment dramatically slows moisture uptake, preserving filament quality and structural integrity over time.

The MATLAB simulation models absorption as a function of time, showing that Mars offers a passive advantage for high-quality nylon manufacturing without the need for energy-intensive drying systems. This supports our claim that Mars is naturally suited for in-situ recycling and additive manufacturing.

This simulation models the temperature behavior of nylon during the extrusion and cooling phases of additive manufacturing. The red curve represents the extrusion temperature, fluctuating slightly around 240–260 °C to reflect real-world thermal control during filament formation. The blue curve shows the cooling curve, which follows an exponential decay. Critical for understanding crystallization and mechanical stability post-print.

By visualizing this process, we demonstrate that recycled nylon can be reliably processed into filament with consistent thermal behavior. This supports our claim that mission waste can be transformed into high-quality components using energy-efficient, in-situ manufacturing workflows.

This simulation models how much nylon material is retained after multiple recycling cycles. Starting with 100 kg of recovered waste, the system retains 85% of material per cycle. A conservative estimate based on current extrusion and reprocessing efficiencies.

The downward curve shows that even after five cycles, over 44 kg of usable material remains, supporting long-duration missions with minimal waste. This validates the feasibility of a closed-loop recycling system on Mars, where every gram counts and resource independence is critical.

By quantifying retention, we demonstrate that our system can sustain infrastructure upgrades and modular repairs without relying on Earth-supplied spares.

This simulation models the gradual loss of tensile strength in nylon due to prolonged UV exposure. A critical factor for outdoor components on Mars. The linear decline reflects how unprotected nylon weakens over time, potentially compromising structural integrity in brackets, insulation panels, or surface-mounted parts.

By quantifying this degradation, we highlight the importance of UV mitigation strategies, such as titanium dioxide coatings or regolith shielding. This supports our claim that recycled nylon can be safely used in Martian infrastructure when paired with protective treatments, enabling long-term durability in harsh surface conditions.

This simulation models the cumulative waste recycled over a 36-month Mars mission. Assuming 30 kg of nylon-rich waste generated per month and a 75% recycling efficiency, the system diverts over 800 kg of waste from disposal. Transforming it into usable infrastructure components.

The linear trend reflects consistent recycling performance, supporting modular repairs, habitat upgrades, and resource independence. This reinforces our claim that Red Planet Recyclers enables zero-launch-weight spare parts and a closed-loop manufacturing system for long-duration missions.