Recycling Lifecycle

Our system enables a closed-loop recycling process for nylon waste generated during Mars missions. By extracting nylon from discarded materials such as food packaging, clothing, and EVA gear, we regenerate it into printable filament and transform it into mission-critical infrastructure, specifically brackets. These components can be reprocessed at end-of-life, creating a sustainable cycle that reduces waste, minimizes reliance on Earth-supplied parts, and supports long-term habitat upgrades.

Step 1: Nylon sourcing and preprocessing

Among the various forms of non-metabolic wastes produced during space missions, synthetic polymers like nylon are near-omnipresent. As a low-cost and highly versatile polymer with great strength, ductility, waterproofing capabilities and a relatively higher melting point than other plastics - anything from great chunks to miniscule traces of nylon can be found in textiles, packaging and containment bags for anything from food, components, gear to EVA waste, to wearables like gloves and masks [1]. Once these items have reached the end of their lifecycle and are disposed of, retrieving and recycling their nylon component will ensure sustainability, and that new things can be made under circumstances where raw materials are limited.

The first steps of retrieving and preprocessing of nylon scraps will involve collecting discarded parts and manually removing as much of the attached nylon as possible from other elements. Initial cleaning to remove organic wastes or Martian regolith may be used. These separated nylon scraps, along with items made entirely out of nylon and blended fabrics containing nylon will then be shredded down for enzymatic recycling.

Step 2: Enzymatic recycling

Enzymatic recycling is a low-energy, biochemical method that breaks down used nylon into its basic building blocks using natural enzymes. These enzymes target nylon 6 and nylon 6,6, converting them into reusable monomers like caprolactam, hexamethylenediamine, and adipic acid. The process works in water-based systems at moderate temperatures and avoids harsh chemicals or high pressure. Once the monomers are recovered and purified, they can be re-polymerized into fresh, virgin-quality nylon suitable for manufacturing.

This method is especially useful for recycling contaminated or mixed nylon waste, such as textiles with adhesives or colored packaging. It supports closed-loop recycling, meaning the same nylon can be reused multiple times without losing quality. On Mars, enzymatic recycling is ideal because it handles complex waste efficiently, requires minimal energy, and helps crews repurpose mission materials into new infrastructure, reducing reliance on Earth-supplied resources.

Step 3: Melting & Extrusion

The high-purity reconstituted nylon can now be turned back into forms usable in manufacturing, by extruding into filament or pelletisation. While the filament form is good for FDM printing and similar application, pellets offer greater versatility, being usable for molding, casting, as well as various forms of deposition 3D printing. Processes to ensure both pellets and filament adhere to strict dimensional standards to be suited for manufacturing (filament diameter of 1.75 mm ± 0.05 mm, pellet grain length 2 mm) are well understood and can be applied. A direct filament-to-pellet pipeline simplifies the manufacturing of both material forms, and one could even extend this pipeline further to have the pellets be ground down into fine powder for higher-resolution 3D printing methods like SLS, should that be needed.

Formation into filament/pellets is where the majority of thermal energy requirements for the nylon recycling process lies. The raw nylon is heated to 240 - 260 °C and is then pushed through a high-precision nozzle (or array of nozzles) to be extruded into filament, and air-cooled to ambient temperature. This filament can then be utilised as is, or further cut down into pellet form. Prior to as well as after this process, the nylon can be kept in 80-90°C for an extended period of time (what would be around 4 hours on Earth, but may be significantly less time on Mars given drastically lower ambient humidity) to ensure that it is dry and ready for processing, use in manufacturing, or storage. Overall moisture levels for the material must be kept under 0.6% to ensure manufacturing reliability.

Step 4: Printing & Molding

The recycled nylon filament is then used to fabricate mission-critical components through additive manufacturing. Our focus is on brackets, which serve as modular connectors for insulation panels, shelving, and other infrastructure elements within the Martian habitat. These parts are designed for ease of assembly and disassembly, allowing crews to upgrade or reconfigure their living space as needed. The printing process ensures precision, repeatability, and material efficiency, all essential for resource-constrained environments.

Step 5: Closed-Loop Recycling

At the end of their service life, printed components can be recovered and fed back into the recycling pipeline. Brackets and other structural parts are shredded and ground into powder, which is then re-dried, re-extruded, and reprinted. This closed-loop system reduces waste accumulation and supports continuous infrastructure upgrades without introducing new materials. The enzymatic recycling process plays a key role here: it allows for repeated breakdown and regeneration of nylon, even after multiple use cycles. Unlike conventional recycling, which degrades polymer quality over time, enzymatic recycling maintains high purity and mechanical integrity, enabling long-term reuse and sustainability.