NASA asked our team to design a storage system that holds tools used by astronauts on the moon and prevents dust from contaminating the spacecraft’s living areas. Lunar dust is sharp and electrically charged, posing risks to both equipment and astronaut health.
We designed and tested a containment system that stores dusty tools and prevents dust leakage during missions. We subjected the system to shaker table testing to simulate spacecraft ascent and descent vibration loads, and the results demonstrated that the system maintained its seal. We verified leak performance by placing tape around the lid seals to capture dust and examining the samples to quantify dust escape.
Due to budget constraints, our sponsor waived NASA’s strict flammability and off-gassing requirements. We built the prototype with cost-effective materials but recommended approved materials for flight applications. We also adhered to volume constraints, ensured the system accommodated suited astronaut operation, and eliminated sharp edges.
Our final design uses polycarbonate, a strong and durable plastic, and incorporates a dual-lid configuration. The outer lid employs toggle clamps to apply uniform pressure around the seal, while the inner lid features a maze-like geometry that forces dust through an extended tortuous path. This dual-lid approach protects the O-ring on the outer lid, the system’s most vulnerable component, from the extremely sharp lunar dust that can cut or abrade the soft O-ring material.
Our system successfully contains lunar dust and protects nearby spacecraft equipment and crew. By addressing dust contamination challenges during lunar missions, our design supports safer operations and advances the next phase of lunar exploration.
