Designing a NASA Research Station in the Atacama Desert

I'm Ronan Tolla, an 18-year-old student attending Livermore High School in Livermore, California. This instructable is intended for the Make It Resilient Student Design Challenge.

In this project, I use Fusion 360 to design a NASA research station in the Atacama Desert in Chile. This project will walk you through the process I used to design the structure and help you learn to create similar structures yourself.

The only thing required for this project is a Fusion 360 license.

• If you are a student you can get a free education license at this link.
• You can get a free non-education license at this link.
• You can get a full license at this link.

When googling through different locations on Earth with extreme conditions, I found the Atacama desert in Chile. The landscape is incredibly unique and is known as the driest location in the world, receiving an annual rainfall of less than 1mm of precipitation. Atacama also has many impressive geological features including massive mountains, salt flats, and geysers. I knew this site's special location would be a perfect challenge for designing a livable human habitat.

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Solving a Problem

Besides the incredible landscape, I also chose the Atacama desert for another reason: NASA frequently uses it for testing Mars rovers.

The Atacama is regarded as one of the closest analogs to Mars' surface and is a perfect spot for rover research and experimentation. The red, rocky terrain with almost no water mirrors that of Mars. The granules of dirt and sand are the same size as Mars regolith. Thus, the conditions are ideal not only for testing the terrain navigation capabilities of a rover but also for the drilling, sample-collecting, and life-detecting capabilities.

NASA's ARDAS experiments are ongoing and once per year a research team camps in the Atacama for 1-2 months to test new rover designs. But this camping situation is not close to ideal. There's no proper space or equipment setup for working on the rovers in between tests and simulated missions. There's no place for researchers to analyze collected data or test samples. There's no human amenities like bathrooms, air conditioning, or proper beds. All this makes it quite difficult to conduct the research the ARADS program is designed for effectively.

This inspired me to design a research facility structure in the Atacama that would allow NASA to test rovers, fix rovers, analyze data, and support a crew of researchers.

Choosing a Specific Location

For the actual site itself, I opted for 24°22'48"S 69°15'58"W. This is near several of the locations that NASA most commonly uses to test rovers and near several roads that are necessary for driving out to the research station. It is also close to multiple different landscapes that can be used for different types of testing including salt flats, flat land, mountains, and hilly terrain.

Furthermore, this location is near the Subestacion Laguna Seca of the BHP Minera Escondida (a large copper mine), which already has water pipelines. This means a new small pipeline can be diverted from the mine to the research station to easily provide running water. Creating a water pipeline from a nearby city or another source would be extremely expensive and time-consuming, and might cost more than the entire research station itself.

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Before starting a design, its important to create a list of constraints for your project. I decided the research station would need 6 parts: a sleeping area, bathroom, kitchen, rover service room, computer lab, and car garage.

Sleeping Quarters

• Beds for 12 researchers
• Should be compact

Bathroom

• Toilet
• Shower
• Sink

Kitchen

• Small Kitchen
• Stove
• Oven
• Fridge

Rover Service Room

• Large vertically opening door
• Toolboxes
• Tables for working

Computer Lab

• 6 computer workstations

Garage

• Only needs to protect cars from sun
• House 3 vehicles
• Place to save on costs

General Constraints

• Design should use environmentally friendly materials
• Focus on resource and energy efficiency
• Materials should be sourced from nearby if possible
• Design should use natural cooling systems to save energy
• Ease of construction must be considered
• Must use standard sizes of real-world parts
• Energy should come only from solar power

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I looked through a lot of desert architecture designs before beginning my CAD. Most of them use relatively simple shapes combined with energy-saving techniques and desert tones that match their surroundings.

In particular, I liked the idea of using a passive cooling system inspired by historical Arabian architecture, and plan on implementing that into my design.

I also learned the importance of considering the orientation of structures and windows relative to the sun. My building will need to have the least open window area to the north.

The large picture here is the Sweeney Granite Mountains Desert Research Center, which I plan to use as an example for multiple design elements. At this research center, along with many other desert facilities and houses, it is typical to build underground as it is much cooler. Thus, I decided that my structure should be two stories with a lower half below ground.

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After deciding that I wanted the structure to be two stories with one underground, I created upper and lower layout sketches.

The upstairs contains the rover service bay for easy access to the outdoors. It also has the bathroom and shower because I plan to add a passive water heating solution that uses solar energy. The kitchen fit well with the remaining space.

The downstairs contains the sleeping quarters and the computer lab because it is more important that these areas stay cool. Computers generate a lot of thermal energy, and putting them upstairs could cause overheating. Your body falls asleep quicker in a slightly cooler environment and it's easier to sleep in an area without light.

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For desert structures, walls need to be well-insulated, avoid absorbing too much heat, be cost-effective, be practical to create given the remote location, and be resilient enough to withstand dust storms and extremely dry weather. Additionally, I wanted my walls to be made of sustainable materials (preferably locally sourced).

Before creating the basic structure of my habitat, I researched several types of wall materials and construction methods. These are the ones I narrowed down my initial search to.

Insulated Concrete Forms (ICFS)

ICFs are hollow blocks made of insulating material (like expanded polystyrene) that are stacked like legos and then filled with concrete or other stone-based fillers.

Advantages:

• High insulation value
• High structural strength
• Very energy efficient
• Partially made of sustainable materials

Disadvantages:

• High initial cost
• Requires skilled labor and understanding of the ICF system
• ICFs aren't readily available in all areas
• Polystyrene insulation is not environmentally friendly

Stone / Rock Walls

Using locally sourced stones or rocks, stone walls can be dry-stacked or mortared.

Advantages:

• Excellent durability
• High thermal mass, providing natural cooling
• Sustainable

Disadvantages:

• Building with stone is time-consuming.
• Require additional insulation to improve thermal performance
• Stones are not always easy to source

Compressed Earth Blocks (CEBs)

CEBs are similar to adobe bricks but are compressed using a mechanical press. The blocks are stacked with mortar to form walls.

Advantages:

• More uniform and stronger than traditional Adobe
• Good thermal properties
• Sustainable

Disadvantages:

• Consistent quality can be an issue between blocks
• CEBs can be susceptible to water damage

Insulated Rammed Earth

Making rammed earth walls involves compacting a mixture of soil, sand, and a small amount of cement or lime into a formwork. Layers of this mixture are placed in sequence until the wall reaches the desired height. This is done twice, and a layer of insulation is placed in between the two walls.

Advantages:

• High thermal mass
• Very durable
• Sustainable
• Uses local materials

Disadvantages:

• Relatively slow
• Not suited for high rainfall areas

Balanced Choice: Insulated Rammed Earth

After thoroughly reading about the many types of wall constructions, I opted for insulated rammed earth as the most balanced choice. Rammed earth is as or more cost-effective than the other options, has a very high thermal mass which makes saving energy easier, and is extremely sustainable. The composition of the Atacama desert soil is perfect for rammed earth, which means that money and fossil fuels will be saved on importing resources, additionally increasing the sustainability and ease of construction. Rammed earth is also as durable as all the other options, without many of the downsides they come with.

The two prominent disadvantages of inuslated rammed earth (slow construction and weakness to rainfall) are not an issue in the context of the research station. The building is small so construction time won't be a concern. And rainfall will obviously not be an issue in the driest place on earth.

Thus, rammed earth was the most balanced choice.

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Walls

Per the recommendations of the US Society of Civil Engineers, I made the structural outside and center walls 18in thick, with the dividing walls 12in thick. I left a 4in gap in the center of the structural walls for insulation but filled the dividing walls. The lower and upper story walls will be made out of rammed earth.

The top of the walls are sloped to fit a slanted roof which will be important later for solar panels.

Dimensioning

Based on the specifications in US building codes, I made the ceilings 8ft tall, doorways 80in tall, windows 36in above ground, windows dimensioned as standard glass pane sizes, and floors/ceilings 8in thick (more on those later).

Foundation

I made the foundation slab 12in, with the full supports reaching 24in further down, also per US building code specifications. The foundation will be made out of concrete instead of rammed earth as rammed earth does not hold up as well as concrete when formed into flat slabs.

Paint

The exterior walls are painted white with a special paint designed in Purdue's FLEX lab that reflects 98.1% of sunlight. This helps keep the building naturally cool even more effectively than traditional white paint.

For the interior, I decided to paint some walls and leave others with the rammed earth exposed. I felt this combination would help to increase the brightness and colors of rooms via the reflectivity of the paint while also maintaining a sort of connection and semblance to nature with the raw browns of the rammed earth.

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Considerations

Before designing the floor, I researched the typical construction techniques used to create floors for different loads and applications.

I was worried that the thick rammed earth walls on the ground level story could collapse the floor if left without extra support, so I decided to run steel beams inlaid into the walls of the lower lever directly under the upper layer's dividing walls.

I also wanted to make sure my design was sustainable by using local and renewable materials. Typically research stations and commercial buildings would use cheaper tiling and supporting options for flooring, but instead, I chose to use wood for the aforementioned sustainability focus and the greater resilience and life span. Pine is the most common wood used for construction in Chile, as it is grown across the country. Thus, the floorboards, subfloor, and supporting joists are all pine.

Additionally, I think the use of wood flooring makes the space feel more like a home and less like a lab, which is important if NASA researchers are spending months there.

Steel Supports

I modeled 2 intersecting S8x6in wide-flange steel I-beams that can be cut and welded together. The ends of the steel beams are inlaid into the rammed earth walls.

Joists and Blocking

The standard joist size and spacing in US construction is 2x8in joists spaced at 16in intervals. This is what I went with for my design. The blocking is also made from the same 2x8in pine beams as the joists.

The joists connect to end/header joists that distribute the load into the supporting rammed earth wall. The end joists sit on sill plates ontop of a small ledge formed into the rammed earth. The blocking provides extra support and helps stabilize the joists.

Subfloor

The subfloor is made of subfloor panels that sit above the joists and below the floor boards. The panels I used are 6x6ft pine based plywood which a thickness of 3/4in (the standard thickness for higher load floors using 16in spaced joists). The plywood is sealed with a water-resistant coating such as Sani-Tread to prevent damage and increase longevity.

The subfloor panels are fixed directly to the joists via screws, and the hardwood flooring can be fixed to the panels after.

Floor Boards

For the hardwood flooring, I used interlocking 8in pine boards. Using modern interlocking boards makes construction easier.

I also added 6x1/2in white baseboards around the rooms.

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When choosing windows for a desert building, mitigating heat from the sun is the most important focus.

Pane Thickness

Windows in desert houses and buildings are typically 2-3 panes thick. The air gap between the panes (sometimes filled with a different gas like argon) provides more insulation that limits heat gain during a sunny day.

Given that I already oriented most of the main windows of the research station to be south or east-facing (this receives the least direct sunlight), I decided it would be safe to use 2 panes instead of 3.

For the interior windows that separate the rover service room from the kitchen and hall, I used single-pane glass to save on cost--heat protection isn't important for these windows.

Window Coating

Low-emissivity coatings on glass help reflect infrared and ultraviolet light, keeping heat out from the sun. Most windows in US houses and buildings have some form of Low-E coatings, but buildings in the desert have coatings rated for higher UV resistance.

There are 2 important factors to consider when choosing a Low-E glass in the desert:

• Solar Heat Gain Coefficient (SHGC): A lower SHGC means better control of solar heat gain
• Visible Light Transmittance (VLT): A higher VLT ensures that plenty of natural light enters your building

I chose to use 6mm Pilkington Suncool 70/35 Low-E Glass with an argon gas-filled cavity because of its good VLT and SHGC values of 69% and 0.26 respectively. The argon gas filling between the panes provides additional sun/heat protection.

Framing in Rammed Earth Walls

In most designs I looked through, windows in rammed earth walls are framed with wood/metal that is partially set into the rammed earth.

I followed this design concept in the research station, adding ridged slots for the windows to mount into on the rammed earth walls. I used aluminum instead of wood framing for improved resilience given the extreme environment.

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The research station needs 3 different kinds of doors with different constraints: a large garage-like door for the rover room, an external front door to the station, and 3 internal doors that divide the various rooms.

Front Door

The front door to the research station needs to be resilient as it's exposed to the harsh outdoor climate. Thus, I made the door a typical commercial steel door with topped with a sun-resistant paint.

The small window in the upper part of the door lets some light in while minimizing heat gain. Ideally the window could be made out of the same Pilkington Suncool 70/35 glass, but its unlikely most door manufacturers make doors with that exact glass inlayed. Instead, a different Low-E glass that the manufacturer supports could be used or a coating could be applied to a normal glass if necessary.

The door is 2in thick with extra foam insulation to prevent heat loss.

The door framing in the rammed earth is similar to the windows in the previous step. A channel is formed in the rammed earth that the metal door frame slots into. However, I made the frame out of steel for the door instead of aluminum like the windows.

I added a brass doorknob as a nice aesthetic touch to the door.

Internal Doors

To save costs for the internal doors, I decided to make them wood instead of metal like the front door. These internal doors can be lighter and less insulated which also saves cost. I used pine wood to match the rest of the station and kept the focus on sustainability and local material use.

Per the recommendations of Rammed Earth Enterprises, I still used steel door framing for the rest of the doors. I used the same mounting system as the external door with bolts and slots in the rammed earth.

Rover Bay Door

The rover bay door is important because it provides an easy way to move the rover in and out of the station. This means the bay door must be easy to use and additionally resistant because it opens to the outdoors.

My original idea for the door was to use a small garage door, however, I realized a better solution for commercial buildings already exists: roll-up doors. Roll-up doors are similar to garage doors in that they open by retracting and folding segments, but roll-up doors are much more compact. They open vertically and use smaller segments to coil around a large axle, sort of like rolling up a roll of paper towels.

I found roll-up doors from the company Dynatech that ship to Chile. They make Gortite Aluminum roll-up doors designed for utility trucks and small buildings out of mostly recycled aluminum. This was an optimal choice for a door that balanced resilience and sustainability long-lasting sturdy aluminum construction and the ability to recycle the door when its lifespan is eventually spent.

To mount the door, there are two large plates on the top of the door's axle I mounted directly to the inside of the rammed earth walls. There are also small extending tabs from the door's rails that I mounted into a small slot in the rammed earth.

This door will also be key to the structure's nighttime cooling system which I'll detail in a later step.

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The garage for the research station only needs to serve one purpose: protecting cars from the harsh weather. This makes the garage a good place to save money and resources as it does not need to be a fully built permanent structure like the rest of the station.

Instead of a full structure, the garage can be constructed like a canvas tent that attaches to the side of the research station. The front of the garage will open like a tent, with a large zipper that opens a flap door.

Concrete Set Steel Posts

To support the canvas tent, I created 7 steel posts set into the ground with concrete. The posts are spaced to fit 3 cars in the garage.

In accordance with US building codes for concrete set fence posts, the posts are 2.4in diameter, 1/4in thick, and triple-coated with zinc.

I set the post 36 into the ground, which is 6in deeper than the standard, but I thought the extra depth could help combat any erosion that could occur around the concrete due to the looser desert soil.

Framing

I connected the vertical concrete set posts via more steel tubing of a slightly smaller 1.8in diameter. Together they form a structure that supports the canvas.

Canvas Material and Attachment

For the canvas material, I chose to use Sunforger Canvas because it is durable, weather reistant, and blocks UV very well, making it fitting for a desert application.

The canvas is stretched around the framing and pulled tight using a basic metal rope tensioner. The bottom end of the tensioning rope is attached to the base of the concrete-set steel poles, and the top is attached to the seam of the canvas.

To mount the canvas where the garage meets the wall of the research station, I used 3/8in Square Pad Eye hooks that bolt directly into the rammed earth. 

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Considerations

To design the roof, I started by looking through roof construction plans and designs by various architects. Specifically, I was interested in how sloped roofs are designed: overhangs, supports, roof panels, etc.

Most sloped roofs are actually quite simple in terms of construction. Thick supporting posts stick up from the walls of the structure, which the rafters are fixed to. Purlins and blocks then join the rafters together. Insulation is placed in between the rafters and held In by ceiling panels or drywall on the bottom of the roof. Above the rafters, a structural support decking like plywood or MDF is used. A thin waterproof separation liner is applied above the structural deck. Atop this, the metal roof panels are layered and screwed into the structural deck using screws with special seals on them.

For sustainability, I chose to use only environmentally friendly resources. I used recycled aluminum roof panels that can be recycled again when necessary and the same pine wood used on the rest of the structure.

Supports

I added 3 rows of 6 supports along the walls of the structure. The supports in the front and rear of the station are 12x12in lumber while the ones in the middle are 12x8 in due to the thinner interior wall.

The supports are fitted directly into the rammed earth using 18in deep square holes that are formed when the rammed earth is formed.

Rafters

Per the US standard, I made the rafters 2x10in. I fixed 2 rafters to each side of the supports, making a total of 12 rafters. The rafters extend 3ft beyond either side of the station for eaves in the front and back.

Purlins

The Purlins are 2x4in running under and perpendicular to the rafters. They provide additional stabilization to the roof and a way to mount ceiling drywall.

Drywall and Insulation

To attach the drywall, it can be cut to size and basic drywall screws can be used to secure it directly to the purlins.

Normal drywall is not very environmentally friendly because of its content and manudtruring process. Instead of a regular drywall, I used a more eco friendly drywall: SheetRock Ecosmart Firecode 30 Panels. I used these panels given these promising statistics

• Up to 25% less global warming potential (GWP)
• Up to 30% less weight reduces transportation fuel energy by up to 20%
• Up to 97.3% recycled content (regionally available)
• Achieved GREENGUARD Gold Certification and qualifies as a low VOC emitting material (meets CA 01350)
• Comply with ASTM C1396, Standard Specification for Gypsum Board, for 5/8 in. (15.9 mm) and non-Type X gypsum wallboard

For insulation, I also chose to use a sustainable alternative to the standard: Premium Icynene Classic 45. This is a spray insulation made mostly from recycled plastics. It also is extremely efficient and effective insulation, giving incredible thermal protection even in thinner layers. Because of this effectiveness, it will save additional energy for cooling the research station by keeping the temperature better.

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Structural Deck and Separation Layer

For the structural deck, I chose simple 3/4in pine-based plywood. It can be fixed directly to the rafters with screws. To create eaves the same size as the eaves made by the rafters, The decking also extends 3ft to the right and left of the structure.

The separation layer goes between the metal roof panels and the structural deck. I chose to use Dorken Delta-Trela Plus for this material as it has excellent durability which will be important in the extreme climate of the Atacama.

Metal Roof Panels

I modeled the aluminum roof panels as a standard extrusion of 1.75in rib height and 18in rib spacing, which will be available at any local roofing manufacturer in Chile.

The BHP Minera Escondida (copper mine) near the research station uses these standard panels on their buildings but I was not able to determine which manufacturer they got them from.

Soffits and Fascia

Soffits are essentially the underside of the roof overhang which cover any gaps in the roof. In the design of this sloping roof, it made more sense to omit the soffits and leave the rafters exposed instead because there is no large roof cavity and attic. Additionally, I think the look of the rafters is more aesthetically appealing as the wood's tone matches the rammed earth walls and the landscape.

The fascia is the edge trim of the roof that covers the exposed roof structure and prevents water from getting under the aluminum panels. I made these 10in x 6in aluminum so they fully cover the rafters and have reasonable extension over the aluminum panels.

The fascia should be available from the same manufacturer that the roof panels are purchased from.

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Roof Eaves Trim

Under the roof overhangs, I added wood blocks between the rafters to enclose the insulation and provide a spot to mount trim. I made this out of 2x10in pine boards, the same size as the rafter boards.

For the trim itself, I chose to use a 1/2in thick wooden trim painted light beige. The beige works well with the metal roof and wooden tones of the rafters/supports.

Station Base Trim

For the base trim that wraps around the bottom of the building, I used the same 1/4in trim boards painted in light grey to match the edges of the roof.

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Hole In The Floor

To make a ladder that connects the lower and upper stories of the research station, I started by creating a large hole in the floor where I planned to do in Step 5: Creating A Layout.

The hole is 32x40in, a rectangle the same height as a doorway but slightly wider. It extends through the floor to make space for the ladder. The edges of the hole are bordered by trim boards that cover the exposed floor structure.

Ladder

The ladder itself is quite simple: a fixed, welded ladder that can be pre bought and bolted into the rammed earth wall. I found a commercial fixed ladder available on Grainger, manufactured with recycled metal by Cotterman. The ladder is 22in wide with 12in rung spacing.

I extended the ladder 4ft above the whole in order to make getting on and off easier.

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Providing natural light in a working area is important. Not only is it more comfortable and bright, but studies have shown natural light to increase work productivity.

Thus, shining sunlight into the lower level of the research station is necessary for the benefit of the researchers. The light can help make working in the lower level's computer lab more pleasant and more efficient.

Additionally, this natural lighting can save energy by using energy from the natural environment instead of using electricity to power artificial light.

Window Placement

To maximize the amount of sun that shines into the basement, I decided to put the windows on the north side of the research station (the lower end of the sloped roof). This area gets the most light due to Chile's location in the southern hemisphere.

Window Size

I made the windows short, only 12in tall and 70in wide. This lets just the right amount of light in -- a bigger window could heat the room too much, and a smaller window wouldn't provide enough light.

Window Construction

The basement window construction is the same as the windows on the upper story. I used the 6mm Pilkington Suncool 70/35 Low-E Glass, double-paned, with the same slots in the rammed earth for mounting.

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On top of the single-sloped roof, there is ample room for a solar power system that can harness the energy of the harsh sun in the Atacama. Solar panels are incredibly efficient in the desert because the sun usually shines year-round unobstructed.

There should be enough space to create a solar power system that provides all the energy the research station should need, eliminating the need to use energy generated via unsustainable and environmentally harmful means.

Solar Panel Size

I chose to use a standard solar panel size of 66x36in, containing 62 cells, producing 400w. This will allow for optimal energy generation and spacing.

Solar Panel and Battery Placement

I placed the solar panels in 5 rows of 8. This covers the entire roof of the research station but leaves room in the corner for a water heating system that I will detail later.

The slope of the roof is oriented with the high point towards the south and the low point to the north so that the solar panels can be mounted in the same orientation as the roof. The panels will face the north, as this is where the most direct sun hits them and they can generate the most power.

I placed 6 large battery packs on the of the research station. Assuming the packs are the equivalents of Tesla's power banks, they store 13.5kWh of energy, meaning six of them can store 81kWh.

Self-Tilting Panel System

One approach to mounting the solar panels would be to mount each solar panel at a fixed angle of 24 degrees based on the research station's location in the Atacama (I used an online calculator to determine this angle.)

However, this angle of 24 degrees is an average of the optimal angle. The real optimal angle for the solar panels to face changes with the seasons and the time of day. Thus, I decided to create a smart, automatic tilting system for the panels that track the sun's position over the day.

I fixed the solar panels to motorized hinges that can tilt to any angle. These hinges are hooked up to a sensor and processor that determine the best angle to move the solar panels to based on the sun's position. The sun sensor is in the upper corner of the roof so the solar panels do not shade the sensor.

This self-tilting panel system will maximize the amount of energy generated by the panels.

Calculating Solar Panel Power

There is a total of 5 * 8 - 3 = 37 solar panels, each rated at 400W.

To convert the power rating from watts to kilowatts: 400W = 0.4kW

To calculate the total power output for 40 panels: 0.4kW * 36 panels = 14.8kW

According to Greenclancer Solar, desert environments usually get 7-8 hours of usable light for solar panels. However, this assumes that the solar panels are at a fixed angle. For these self-tilting panels, I'd estimate that there is at least 9-10 hours of usable sunlight. To stay on the safe side, I'll assume that these panels receive 9 hours of good sunlight.

To calculate the daily energy production: Daily Energy (kWh) = 14.8kW * 9hours/day = 133.2kWh per day

133.2kWh per day is easily more than enough energy for the research station. For reference, the average US home uses 29kWh per day. While it's likely the research station will use more than an average home because of the copious amounts of technology (6 computers, laptops, charging rover batteries, etc.), it is still making over 4x the needed power for a normal home.

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The easiest way to get hot water in the research station would be to install a water heater that uses gas or electricity. However, a more environmentally friendly solution is available: the sun. A commercially available solar water heater can be easily installed on the station's roof and uses only sun energy to heat water, eliminating the need to use gas or electricity.

Water Heater Size and Placement

In the lower right corner of the sloped roof, I added 2 solar water heaters. Each water heater holds 60 gallons of water in the large tank above the heating pipes, for a total of 120 gallons of hot water. The heaters sit directly above the shower and bathroom sink to make piping simpler.

How It Works

The solar water heaters have 3 main components: a storage tank, evacuated tube collectors, and a controller. They work together as follows;

The evacuated tube collectors (the black long tubes) absorb solar radiation and convert it into heat. Each tube contains an absorber that heats up from the sun. The well-insulated storage tank stores the heated water for later use. The controller ensures that the system operates efficiently, using sensors and a pump to circulate the water or heat transfer fluid.

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In the Atacama desert, the coolest time of day is during the night. The temperatures in summer can regularly dip as low as ~65 degrees Fahrenheit. Consequently, the best time to cool the research station is at night, when the cool air can be let inside.

To utilize this in an energy-efficient method, I wanted to implement a nighttime cooling system that draws in cold air automatically. I came up with a simple concept: a system of self-opening doors and self-activating fans that can pull cold air through the building at night given that the weather and temperature conditions are right.

This approach requires 5 parts: a system controller, fans, a fan shutter, meteorology instruments, and electronic door openers.

Fans

In the kitchen of the research station, I added 2 large fans above the ladder. The fans are mounted directly into the rammed earth wall to pull air from inside the building out of it. They mount into the rammed earth via slots and bolts.

The fans will only activate at night given the right weather conditions, determined by the controller (more on that in a second in the System Controller section).

Fan Shutter

An important issue arises when mounting these fans into the rammed earth walls--it provides a way for hot air to flow back into the research station during the daytime. This would completely negate the usefulness of the fans unless something is stopping the airflow when necessary.

To combat this issue, I created a fan shutter that sits on the outside of the station where the fans exhaust. The shutter is made from sheet aluminum with a layer of insulation on the inside. When the shutter closes, it sits flat against a sun-resistant rubber seal, preventing air from escaping or entering the research station. The shutter is attached to a linear actuator that can retract to raise the shutter and extend to lower it. This linear actuator is electrically controlled to automatically open when the fans turn on.

Electric Door Openers

In the same way the fan shutter opens when the system turns on, some doors of the research station need to open automatically to allow air to flow through the building. Specifically, the rover service room roll-up door (the big metal one) and standard interior door (the one that connects the rover service room to the other rooms) need to open.

To open the roll-up door, nothing special is needed. The system controller can be wired into the switch that operates the roll-up door's motor.

To open the standard interior door, I added an electric door opener. I designed it based on the common, commercially available handicap door openers. Here, instead of pushing a button with a wheelchair logo that opens that door, the door can be opened automatically by the system controller.

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Meteorology Instruments

For this automatic cooling system to activate only during the right conditions, a small weather station is needed to actively determine what those conditions are. I modeled the weather station on the right edge of the roof where it can get accurate readings. The instruments mount to a post made of recycled aluminum.

The weather station is equipped with an anemometer to determine wind speed and direction. This data is useful to see if it's too windy to open the research station's doors. In the Atacama, high winds will pick up dirt, dust, and sand that would be detrimental to the research station if blown inside. Desert sand storms can also occur which would be particularly bad for the station.

Rain is almost nonexistent in the Atacama (the driest place on earth), but in the rare chance that it does rain, it's useful to know how much. Thus, I included a rain gauge in the array of meteorology instruments. The station doors can also be programmed to stay closed if rainfall is detected. To detect if it is likely to rain, a hygrometer (humidity sensor) is also included on the weather station.

The most basic instrument, a thermometer, is of course included in the weather station. The temperature data can be used to determine the specific time to open and close the research station's doors and turn the fans on/off. I'll detail exactly how it can be used in the System Controller section.

Additionally, the weather station provides useful information about the weather and temperature to the NASA researchers. Not only does it give current info about the climate conditions, but it also produces data that can be used to help accurately predict the local weather patterns--important information for planning rover tests.

System Controller

All the other parts of the nighttime cooling system depend on one thing to work together: a controller. The system controller takes the data from the weather station and decides whether or not to tell the fans to activate, the fan shutter to open, the roll-up door to retract, and the electric door opener to open.

Assuming that activating the system entails turning on all aforementioned components (roll-up door, door opener, fans, fan shutter), the system controller can be programmed as follows:

• Only activate the system between the hours of 9pm to 6am
• By default, plan to activate the system at 9pm
• If the temperature outside is higher than the temperature inside, do not activate the system until the temperature outside is lower than the inside temperature
• If the wind outside is higher than 7mph, do not activate the system until the wind speed is below 7mph (7mph is the speed at which wind picks up sand)
• If the rain gauge detects any water, do not activate the system until it has stopped raining
• If the inside temperature drops below 66 degrees Fahrenheit, turn off the system until the inside temperature has been raised above 66 degrees.

Additionally, the system controller can be used to input manual commands to turn and off the system, change the time frame it operates on, and change the temperature shutoff thresholds.

I placed the controller inside the doorframe of the roll-up door for the rover service room.

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Bathroom

The bathroom has 2 components: a toilet and a sink.

I modeled the bathroom sink in the corner of room, on the same wall as the doorway. The sink is a simple design with a faucet, large basin, and 2 cabinets below the countertop. The countertop of the sink is made from marble, which I chose because it is mined locally in Chile. Additionally, I think the marble countertop contrasts well with the texture and tones of the rammed earth walls and makes the space feel more natural. The countertop is 34in high, which is the standard height for the US. The cabinets below the sink countertop are made from pine wood, painted white to match the marble countertop.

I placed the toilet in the corner of the room opposite the doorway. It is modeled after a basic commercially available toilet available from any manufacturer like Kholer. More importantly, the toilet is water-efficient, using only 1.1 gallons per flush. Saving water is important in the world's driest desert.

Shower

The shower is in an adjacent room to the toilet and sink. The reason I separated them is so that the shower can be used independently from the toilet, which is useful if the research station has a lot of people in it.

I designed the shower to be a walk-in shower built with water conservation in mind. The shower head uses only 1 gallon of water per minute, far less than the standard 2.5 gallons per minute found in many US buildings. This means a 5 minute shower will only use 5 gallons of water, a fair improvement from the 12.5 gallons a normal shower head would use.

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For the kitchen design, I wanted to create something with energy and resource-efficient appliances and a color scheme that matched the natural tones of the research station and desert.

For the kitchen cabinets, I modeled an L shape layout in the corner or the kitchen, leaving space for a fridge and oven. I then made lower and upper cabinets and a countertop. The countertop is marble to match the bathroom and for the same sustainability reasons listed in the previous step. It is 36in high and 24 in deep, as that is the standard in the US. The cabinets are made of pine wood, with the doors finished and the rest of the cabinet painted white. This creates a nice contrast between the red-brown walls and desert and the cabinets, while bringing natural tones out that match on the cabinet doors. The handles are brass to keep with this color scheme.

The stove and oven can be sourced sustainably by a manufacturer that uses recycled materials. The stove is a glass-top induction stove because they are the most energy-efficient and eliminate the need for gas. The fridge is a simple extra large 2-door aluminum fridge. The dishwasher is also standard, commercially available, and uses recycled materials.

The kitchen sink has a large aluminum basin that makes washing dishes easy. The sink faucet is water efficient and limits the flow of water. This sink is also made from recycled aluminum. I positioned the sink in front of the large kitchen window--whichever unlucky researcher gets stuck on dish duty has a nice view while they clean dishes.

All of the appliances in this kitchen will have the 'Most Efficent' Energy Star rating.

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Instead of leaving the hallway as empty space, I opted to make it into a high counter top to eat/work at.

I made the countertop out of pine, 20in deep, and oriented towards the rover service room. The internal windows in front of the countertop allow anyone sitting there to watch the researchers tend to the rover. The supports for the pine countertop are steel tubing that mounts directly into the rammed earth.

I made a row of stools that can be tucked underneath the countertop for storage. The stools are pine wood and steel.

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The rover service room really only needs 4 main components: large tables to work on, lots of toolboxes, machine tools, and (of course) a rover.

Work Tables

I made two 60x100in tables to work on, centered in each half of the room. The tables have a thick metal base and have 3in pine table tops for extra resilience. I designed these tables based on the tables my school's robotics team uses for assembly and metalworking.

Tool Boxes

Large toolboxes can easily be found at any hardware store from brands like Craftsmen and Bosch. The toolboxes are the standard size of 26.5x18in. Looking online, I found the CAD for the Craftsman toolbox available on their website. I downloaded the CAD, inserted the toolbox into my design, and arranged 5 of them along the right wall of the rover service room.

These can hold tons of hand tools and spare components that NASA researchers might need to repair a rover, including

• Torque wrenches
• Ratchet wrenches
• Socket sets
• Screwdrivers
• Pliers
• Utility knives
• Calipers
• Micrometers
• Laser levels
• Wire brushes
• Metal files
• Sandpaper
• Deburring tools
• Wire strippers
• Crimping tools
• Soldering irons
• etc.

Machine Tools

According to an interview with a NASA mechanical engineer, the most basic and most used machine tools for working on a rover are lathes, mills, CNCs, drill presses, and belt sanders.

Given that a full machine shop isn't really feasible for a research station, it doesn't make sense to try to fit all these full size machines in the rover service room. Instead, I opted to include 3 mini versions of just the mill because it is the most versatile and most important for making any last minute changes/fixes to the rover. These desktop-sized machines are manufactured by many companies for hobbyists and small businesses, meaning they won't be hard to find commercially available at a nearby supplier in Chile.

To set the machines on something stable, I modeled another 36in tall counter using the same construction as the kitchen and bathroom cabinets. The marble countertop is especially important here because the machine tools are more accurate and safe when mounted to a solid heavy surface.

I modeled a simple drill press, lathe, and mill on the countertop.

The Rover

Looking online, I was able to find an STL for the Perseverance Mars Rover. This is not the rover that NASA would be currently testing in the ARDAS program given that it has already launched, but for representational purposes it works just fine. Unfortunately I couldn't get a STEP file of the rover, which means the whole thing is white and has lines all over it.

I downloaded and inserted the rover STL into the design and positioned it in the center of room. The tables, toolboxes, machine tools, and door to the rover room are arranged so that working on the robot in the center of the room is easiest. It gives the rover a clear path in and out of the roll-up door for testing.

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I left a large room in the lower story of the research station I designated for 2 purposes: a sleeping quarters for the researchers and a meeting area for discussing plans. For the meeting area, I decided it needed a large table with many seats and a TV for holding meetings to discuss plans/objectives. For the sleeping quarters, I established earlier that the station would need room for 12 researchers to sleep, which I could accomplish in a space-efficient manner via bunk beds.

Meeting Area

I started furnishing the meeting area by adding a large rug in the far side of the room. The rug makes the space more comfortable and inviting, especially with the contrast between it and the concrete foundation floor. Instead of buying a commercially manufactured large, I decided to source the rug from a sustainable and culturally important source: a local Chilean rug weaver. Working with fabric and creating geometric patterns is a big part of Chilean culture and heritage. Additionally, I think the way the tones of the rug match the Atacama's colors is fitting for the room.

On top the carpet I made a table and 10 stools on either side of it. This table and stool set is made from recycled steel and locally grown pine wood. The table is the perfect spot to hold meetings, eat lunch, play games, or even watch TV. I modeled a wall mounted 75in TV at the head of the table that can be used by researchers to display any necessary information for meetings, like showing rover designs, maps, a list of objectives, etc.

Sleeping Quarters

For the sleeping quarters, I made 6 recycled steel bunk beds space across the other side of the room. The bunk beds are sized as extra-long twin beds. Each bed holds 2 mattresses, providing sleeping space for a total of 12 people. I chose to use bunk beds specifically because they are more space-efficient and require fewer resources to manufacture.

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In the computer lab, I planned to have 6 workstations, meaning 6 desks and 6 computers.

Wrap-around Desk

Instead of having 6 smaller desks, I opted to create one large desk that wraps the perimeter of the room, as it seemed like a more efficient use of space.

The desk has a pine wood table top that slots into the rammed earth and is secured with bolts. To support it, I added 2.7in outer diameter recycled steel tube desk legs under the tabletop that bolt into the tabletop. These are spaced at 60in intervals to provide lots of movement room for rolling chairs. They also include small rubber feet for better grip.

On the underside of the tabletop, I added 2 pine drawers per desk leg that can be used for storing papers and other desk supplies. The drawers are 4x14x16in.

Computers

Starting with computer peripherals, I modeled a basic mouse, keyboard, and monitor. The monitor is a 27in 1080p Acer monitor.

For the computer specifications, I wanted to do something a little more in-depth. I make computers as a hobbie, so I'm quite familiar with choosing computer specifications to optimize a computer for specific applications. The research station computers will be used by NASA researchers for coding, simulation, CAD, and a variety of other simpler tasks.

I chose the following specifications for the computers to optimize for the aforementioned demanding tasks:

• CPU (Central Processing Unit): Threadripper 5965x

NASA primarily uses Catia V5 and Solidworks for CAD, which are largely CPU-based softwares. This means a very powerful CPU is needed. I chose the Threadripper 3970x because of its high core count of 32 cores and boost clock of 4.5ghz, which makes it ideal for CAD.

• CPU Cooler: NZXT Kraken 360

I chose this CPU cooler because it is very energy-efficient and has great cooling. It uses an AIO water system to cool the CPU.

• GPU (Graphics Processing Unit):

While the CPU is more important for CAD, the GPU is used more heavily in simulations. Thus I chose to use the Nvidia RTX 5000 ADA, featuring 12,800 CUDA cores that accelerate the simulation speed.

• Mother Board: Gigabyte TRX40 Aorus Master

This motherboard fits the cooler and CPU, and has high memory bandwidth, so it was an easy choice.

• RAM (Random Access Memory): G.Skill Trident Z 128 GB

I chose this RAM because it is 128gb of DDR5 5600mhz, meaning it is very fast and can hold a ton of memory, which is important for CAD, simulation, and programming.

• Storage: Samsung 990 Evo

4TB of Samsung 990 Evo storage is plenty of fast storage that can be used for storing anything the researchers need.

• PSU (Power Supply Unit): SeaSonic PRIME TX-1600 ATX 3.0

This 1600w power supply will meet the heavy demands of the CPU and GPU under load. It also has an energy-efficient mode so that it can use less power when not doing a demanding task.

• Case: NZXT H7 Flow

The NZXT H7 flow is a fitting case for this computer build because it is simple, fits the parts, and has good air flow.

I arranged the 6 computers at the desk spaces with 6 of each of the peripherals.

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To light the rooms, I decided a simple solution was better than a complicated one and stuck with basic circular ceiling rights for the whole building.

To be environmentally friendly and energy saving, the lights are all LEDs because they last longer and are more power efficient. I made the lights 2 standard sizes, 6in and 16in, so that they can be found easily at any hardware store. The rims of the lights are all a burnt orange to match the rammed earth and Atacama colors. I included 9 lights downstairs, 7 lights upstairs, and 4 lights outside.

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A LEED certification is a globally recognized symbol of sustainability achievement in buildings. LEED-certified buildings are classified into four levels based on the number of credits earned: Certified, Silver, Gold, and Platinum. A LEED scorecard is used to determine the number of credits a building gets.

The LEED scorecards for LEED v4.1 Building Design + Construction has 9 categories:

Location and Transportation

• Credits for choosing a sustainable location, reducing the need for transportation, and providing alternative transportation options.

Sustainable Sites

• Credits for site selection, design, and management that minimize the impact on ecosystems and water resources.

Water Efficiency

• Credits for reducing water consumption, using water-efficient appliances, and innovative water management systems.

Energy and Atmosphere

• Credits for improving energy performance, using renewable energy, commissioning building systems, and managing refrigerants.

Materials and Resources

• Credits for using sustainable materials, reducing waste, and promoting the use of products that are responsibly sourced.

Indoor Environmental Quality

• Credits for improving indoor air quality, heat management, lighting, acoustics, and occupant comfort.

Integrative Process

• Early analysis of energy and water systems to identify synergies.

Innovation

• Credits for innovative strategies and exemplary performance beyond the requirements in the LEED credits.

Regional Priority

• Credits for addressing geographically specific environmental, social equity, and public health priorities.

On the US Green Building Council website, there is an interactive scorecard that allows users to see if a building meets the requirements for a LEED certification. To evaluate the sustainability of my design, I used the website to determine if the Atacama research station could earn a LEED certification if it was built in real life.

My scores were as follows:

• Location and Transportation (1/16)
• Sustainable Sites (7/10)
• Water Efficiency (10/11)
• Energy and Atmosphere (31/33)
• Materials and Resources (11/13)
• Indoor Environmental Quality (10/16)
• Integrative Process (1/1)
• Innovation (5/6)
• Regional Priority (4/4)

This earned me a total of 80 credits, which is exactly enough for a LEED Platinum certification awarded at 80+ credits.

I was not aware of how LEED certification works when I started this project, and I definitely did not expect to get the highest platinum rating, but I believe this certification is a true testament to the success of the design and to what I've learned through making this Instructable.

I also noticed the weakest area of my design's sustainability when scoring it--transportation. The transportation credits are difficult to get for a remote building like the station, as most of them focus on using preexisting forms of public transport, using new forms of sustainable transport, and protecting the building's surrounding natural habitats. In hindsight, something I could have improved in this area would be to add electric car chargers to the garage, promoting the use of electric and environmentally friendly vehicles for transport. If I design another building, I'll be sure to keep sustainable transport in mind.

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I created a ton of awesome renders of the research station to show the finished product. Unfortunately, I couldn't find any HDRIs of the Atacama, so I made the background a brunt orange.

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What Did I Learn?

Through the process of working on this instructable, I've learned tons about architecture, design, and engineering. I learned about the different kinds of sustainable materials used in buildings, the many construction techniques that go into working with rammed earth walls, how to texture and light a building, the design of roofs and floors made of wood, the ways to use an environment to enhance a structure, how to create an energy-efficient cooling system...

The list of specifics goes on and on and on. But overall, the most important thing I learned was the ability to leverage sustainable design to benefit humans in a built environment. It's not just learning to research construction/design techniques, building standards, and sustainable materials, but also learning how to combine and optimize every aspect of a space in a sustainable way that enhances the human experience.

In addition to this, I learned more about fundamental CAD skills applicable to more than designing buildings. I learned to use Fusion 360 much more efficiently and quickly. I also learned to organize my CAD better, using components and folders that make editing the design much simpler.

How Can I Apply What I Learned To My Own Community?

In my own community, there's many ways I can apply what I learned about sustainable design in both my personal life and the plans of the city.

Personally, I can influence the choices my parents make regarding home renovation. We are planning on replacing our carpet this year with wood. Having learned to find sustainable material options online that can be sourced at local locations, I can suggest companies to purchase hardwood flooring from that use sustainable growing practices and focus on low-emission manufacturing. If we ever need to redo the insulation in out house, or construct a new wall, I now know about the different types of insulation and which are more environmentally friendly. I can use the knowledge I gained in this project to help my parents choose the best sustainable materials. When I'm old enough to own my home, I will also continue to use this knowledge in making building decisions.

In my city, Livermore, I can also have an impact on changing the process by which my city constructs new housing. Recently, the city approved a plan to build more high-density housing downtown. However, they did not make commitments to using sustainable design practices throughout the new buildings. I could attend a city hall meeting to speak about the issues in the current design and how they could be altered to be more environmentally friendly before they are constructed. Using the design experience and knowledge of sustainable construction I gained through making this instructable, I could suggest recycled/recyclable material alternatives, green ways to generate electricity via the sun and wind on the building, and efficient ways to cool and insulate the structure.

Final Words

In conclusion, I loved having the opportunity to hone my CAD skills and learn sustainable building design. The thinking process behind making a sustainable building is something I'm especially happy to say I can take away from this project.

This project has also reinforced my dream of becoming an engineer, and I now plan on pursuing a degree in Mechanical Engineering in college.

I'd like to thank the Instructables team for creating a fun challenge that benefits a ton of young architects/engineers like me.

Best,

Ronan Tolla