Expandable Space Module Technical Recommendation Report

To: John Doe, CEO

From: Madison Maloney, Aerospace Engineer
Subject: Technical Advancements in Expandable Modules for Space Exploration
Date: March 17, 2017

Purpose
This report analyzes the newest innovative module composing the International Space Station,
the Bigelow Expandable Activity Module (BEAM), and provides an informed recommendation
for potential use of expandable space modules. Bigelow Aerospace invented and developed
BEAM, and the National Aeronautics and Space Administration (NASA) directs use of the
module aboard the International Space Station. This report is based on research from Bigelow
Aerospace as well as NASA.

Summary
Expandable space modules are space habitats that can be condensed in size for launch and
inflated once deployed. The Bigelow Expandable Activity Module is the first expandable space
habitat to be tested in space. BEAM is composed of several protective layers, an inner gas
bladder, and a docking and berthing port. Expandable space modules like BEAM could be used
as habitats for astronauts traveling to distant destinations such as Mars and even as habitats on
other orbital bodies themselves. BEAM is quite different from traditional modules, which are
deployed in the same physical state in which they are launched. Expandable space modules are
advantageous for their compressibility, lightweight nature, noise reduction, and x-ray protection.
However, the concept of expandable space modules is still novel, and BEAM has only been
tested for less than two years. BEAM and the concept of expandable space modules have shown
great promise, but further research and testing may be favorable before additional
implementation.

Description
An expandable space module is a space habitat that is packed into a condensed geometry and
inflated upon deployment. It was developed as a space-saving solution for rocket payloads, as
space for missions to distant destinations will have a lot of material to carry. Expandable space
modules are intended to be used by space exploration companies and agencies for such missions.
This is an alternative to traditional space habitat modules, which do not change size from transit
to deployment and are made of much more rigid material. The Bigelow Expandable Activity
Module (BEAM) is the first expandable space module to be tested in space. It is currently
docked to the International Space Station, which is composed of several traditional space habitat
modules. BEAM is made of several layers of material, which are both flexible and durable, an

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inner gas bladder, and a docking and berthing port. The layered wall is unique to BEAM, as all
other station modules have hard aluminum shells (NASA).
BEAM was launched aboard a SpaceX
Dragon rocket in its condensed form,
occupying less than 25% of its expanded
volume (NASA, Bigelow Aerospace). Once
it was docked to the station, it was
pressurized, resulting in gradual expansion,
which can be shown in figure 1. The module
is filled with various sensors, measuring
temperature, pressure and radiation.
Additionally, astronauts enter BEAM
periodically to survey the structural
condition of the module (Seedhouse). BEAM Figure 1: These four images show the
is used primarily as a research vessel and is progression of the expansion of BEAM upon
expected to provide valuable information to deployment from the International Space
advance future expandable space habitats. Station ([Link]).

Physical Features
The walls of BEAM are made of several layers of materials, weighing approximately 25
kg/m2 (Seedhouse).
o The first layer is composed of two sheets protective
of aluminum foil. This layer is responsible layers
for thermal insulation and micrometeorite
vaporization (Seedhouse).
o The next several layers are comprised of
thicker metal sheets, which also insulate
BEAM. These layers protect the module
from damaging encounters with larger
micrometeorites which are not destroyed
by the first layer (Seedhouse). gas
o The innermost layers are made of a bladder berthing/docking
polymer called Vectran. They serve as the port
final line of defense against BEAM Figure 2: Labeled cross-
penetration (Seedhouse). If penetration section view of BEAM
were to occur, BEAM would leak slowly (Bigelow Aerospace).
rather than instantly bursting (NASA).
The interior of the BEAM is referred to as the gas bladder. This is the area in which
testing equipment is mounted and crewmembers can enter (NASA, Bigelow Aerospace).

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 BEAM features a berthing and docking port which allows its position to be manipulated
by a robotic arm aboard the station. This port also affords docking to a compatible
receiving port on the station (Seedhouse).
One of the major distinguishing factors of BEAM is its difference in size before and after
expansion, as shown in table 1.

Packed vs. Expanded BEAM Size

Mass Length Diameter Volume
Packed 1400 kg 2.16 m 2.36 m 3.6 m3
Expanded 1400 kg 4.01 m 3.23 m 16 m3
Table 1: This is a comparison of the physical size of BEAM before and after expansion.

Application
The use of expandable space modules is not reserved to International Space Station docking.
That is simply the first step toward applying the concept to various other missions. One potential
application is attaching an expandable module to the vessel carrying astronauts to deep space
destinations such as Mars. This would allow the crew to have ample space without occupying too
much rocket volume during launch (Seedhouse). Expandable space modules could additionally
be implemented for missions in which habitation occurs on the surface of another orbital body.
This could include habitation on the surface of Mars or an asteroid (NASA).

Comparison with Other Modules

BEAM is distinct from traditional space habitat modules because of its compressibility and
material composition. Traditional space habitat modules feature hard metal walls and launch at
the same size they are deployed. BEAM is smaller at launch than it is after full expansion. It has
a comparable mass per unit docked volume to traditional modules but has a significantly greater
mass per unit launch volume, which is desirable for space efficiency on rockets (NASA). Table 2
highlights key size differences between BEAM and three traditional space habitat modules
currently docked to the International Space Station.

Size Comparisons of BEAM and Traditional Modules

Volume Volume Percent Mass per Mass per
Module Mass at While Change in unit Launch unit Docked
Launch Docked Volume Volume Volume
3 3
BEAM 1,400 kg 3.6 m 16 m 344.44% 388.9 kg 87.5 kg
Columbus 10,297 kg 115 m3 115 m3 0% 89.5 kg 89.5 kg
3 3
Tranquility 17,992 kg 95.9 m 95.9 m 0% 187.6 kg 187.6 kg
3 3
Kibo 15,898 kg 169.2 m 169.2 m 0% 94.0 kg 94.0 kg
Table 2: This is a comparison of several size factors between BEAM and three traditional space
habitat modules on the International Space Station (NASA, Wright).

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Advantages
BEAM exemplifies the advantageous qualities of expandable space modules in its size and
abilities. It has a lightweight and compressible design, reduces noise, and protects against x-rays.
The development of this module and continued research on expandable space moduless is driven
by these advantages.
Lightweight: BEAM is considered to be lightweight. This reduces fuel costs by
decreasing potential payload weight in the rocket (NASA).
Compressibility: By having the ability to be folded into a compact geometry, BEAM
saves a lot of space on launch rockets. This can allow other payloads to fit if needed.
Deployment volume is not sacrificed by space reduction because of the expanding nature
of BEAM (Seedhouse).
Noise Mitigation: Due to the fact that BEAM is made of layers of materials rather than a
traditional metal encasement, noise within the module is reduced. This is an important
factor for inhabitability (NASA).
X-Ray Prevention: Unlike traditional space habitat modules, BEAM prevents passing
cosmic rays from forming secondary high-energy x-rays, which is beneficial for crewed
missions (Seedhouse).

Disadvantages
While BEAM and expandable habitats in general may be popular for their size features, some
other notable factors should be taken into consideration such as the time it takes to inflate it and
the fact that it is still a new technology.
Set-Up Time: Unlike traditional modules, expandable space habitats like BEAM must be
pressurized and enlarged. It took several hours for BEAM to fully expand upon initial
deployment.
Novelty: BEAM has not been tested or utilized as long as traditional modules, which may
lead to safety concerns. Potential applications for expandable space modules would
necessitate durability over a period of time that has not yet elapsed for BEAM.

Recommendation and Conclusion

Expandable space habitats are an intriguing option based on size, compressibility, noise
mitigation, and x-ray protection. BEAM has provided a means of studying such a habitat in its
intended environment, but the module is fairly slow at expanding and is not proven for long
duration missions at this point. Since most of the potential uses for expandable space modules
involve long duration missions, I suggest waiting to implement an expandable space module
design until further testing is performed to ensure the safety of our clients and payloads. I think
research and development performed by our company in the meantime could be beneficial to the
advancement of the concept and may even afford a potential partnership with Bigelow
Aerospace.

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References
Bigelow Aerospace. "Bigelow Aerospace | BEAM." [Link]. N.p., 2016. Web.

16 Mar. 2017. <[Link]

NASA. "Bigelow Expandable Activity Module (BEAM)." [Link]. NASA, 15 Mar. 2017.

Web. 16 Mar. 2017.

<[Link]

N.d. [Link]. Web. 16 Mar. 2017. <[Link]

content/uploads/sites/240/2016/05/expansion_progress8.jpg>.

Seedhouse, Erik. "Bigelow Expandable Activity Module." Bigelow Aerospace: Colonizing Space

One Module at a Time. New York: Springer Praxis, 2015. 87-98. Web. 16 Mar. 2017.

Wright, Jerry. "Columbus Laboratory." NASA. NASA, 13 Apr. 2015. Web. 16 Mar. 2017.

<[Link]

Wright, Jerry. "Kibo Laboratory." NASA. NASA, 09 Oct. 2013. Web. 16 Mar. 2017.

<[Link]

w>.

Wright, Jerry. "Tranquility Node." NASA. NASA, 11 Oct. 2013. Web. 16 Mar. 2017.

<[Link]

3vkrI2w>.