The Desert Star

CAD - It allows me to bring my ideas to reality. In the quickest way possible. In the form of a render or a 3D print. I can have my thoughts in my hand in just a few hours.

And the opportunity to enter my CAD for this competition is one of the reasons that drew me in to this contest.

I like my designs to have a positive impact on the world. It is what fulfils me most. It’s what wakes me up in the morning. So, considering the brief, this contest felt like the perfect opportunity to write my first Instructable and enter it into my first contest.

My idea is designed to be used mainly in desert environments. However, I picked this option as it can be most widely used. For example, although it is suited to deserts, it can also be deployed after a natural disaster to provide safe homes for displaced people. It can also be used as a mobile home for people travelling long distances across an extreme environment such as Antarctica or the Sahara Desert.

My design does not aim to be a shield against the desert or any extreme environment in which it may be used. It aims to instead work with the environment, using the strong winds and intense solar rays, for example, to help the inhabitants thrive. I deigned this habitat to ride and thrive with the environment in which it is placed, and not to push or resist against it.

I also wanted my design to be as easily transportable and accessible as possible. Therefore, for me, my design needed to have parts which could be folded inward to create a smaller volume whilst the design was transported. It also needs to be transportable by either a tow from an SUV or an airlift from a helicopter.

The design was developed with the idea in mind that it will be used for extensive lengths of time. I spent a lot of time researching the psychology of design and how it can help maintain harmony between the users upkeep mental health. My opinion is that the psychological design aspect just as important as the mechanical design.

Supplies for the Prototype

• FDM 3D printer with filament
• Pliers
• Filler primer
• Sand paper
• Clear acrylic (3mm thick stock sheet)
• Laser Cutter
• Epoxy Resin
• Clear Tape
• Tape

Option 1 - Spray paint the prints

• Chrome spray paint
• Black lacquer spray paint
• Filler primer spray paint
• Removable tape

Option 2 - Electroplate the prints

Essentials:

• PPE: gloves, goggles
• Copper conductive spray paint
• Electroplating tank: PP or HDPE plastic or glass
• Electrolyte chemicals - This can either be bought or made from scratch
• Water: distilled, deionised, or pure water (not tap water)
• Brighteners and Levellers
• Electrical connectors: wires, copper wire, bus bar
• Power Supply: adjustable, or fixed output when using the current controller
• Anodes- In this case, Nickel or any silver metal can be used
• Anode Bags: PP PES or Nylon rated below 10 microns (ideally 1 micron)
• Cleaning Chemicals

Extras:

• Tank Heater
• Electrolyte Filter
• Electrolyte Agitator
• Rinse bottle
• Extra Tanks
• Extractor Fan

I have attached the rough notes and sketches that I made during the ideation process to finally reach the final design. 

The first image (Ideation 1) was my start. Here, I sketched out my first few ideas and explored them further. I tried to come up with as many iterations and ideas as possible. Each idea helped me create multiple new ideas from the previous one.

In Ideation 1 I experimented with moving parts and shapes. I experimented with expanding boxes on the side, like those on a caravan. I experimented with interlinking designs, so that multiple of the same habitat could combine into a community, as illustrated by the collective circle concept. After some deeper exploration of triangles, I decided that there should be three triangles attached to a triangular main body, and that next to these triangles should be an expandable box. This looked like an efficient solution. However, it needed optimizing. I decided the triangles could fold in and out after transport to form bedrooms, and that the boxes could be expanded outwards to form extra storage or working space.

I found the ‘Tri’ triangular bedrooms to be very efficient. They provided a large bedroom space when folded out and did not take up very much extra space when folded.

I came up with the idea of a central storage hub that would be in the middle of the design. This would provide a central easily accessible storage space as well as dividing up the main area. I was so far unsure as to the orientation that this should take.

In Ideation 2 I sketched and experimented with orientations, shapes, proportions, and motion of components. I circled all my best ideas for the individual designs or concepts of each component. These were selected for the final design. I also quickly wrote down some notes at the bottom of this page.

I decided to offset the expandable box so that it took up the majority of the side length space. This was due to the Tri bedroom being unnecessarily wide. It also improved the efficiency of the design, as the Tri bedrooms took up significantly less space. 

I experimented with the angle of the roof. My idea was that at the very edges it would be too short to stand, so these areas would be used for storage. However, the vast majority of the space would be more than enough for standing. However, people over 2 meters tall would be uncomfortable in this habitat. This was a trade-off I had to make between accessibility to very tall people and overall height and weight of the design. I decided upon a low slant angle and high edges.

I also decided to expand the Tri bedrooms all the way up to the expandable sides, so that all space was to be used.

I decided that the windows should be covered by an adjustable foil curtail, as foil is very good at reflecting heat. I also decided that these windows should be triple glazed, with an argon cavity in between each plane to increase heat resistance and to keep the temperature inside the habitat at a reasonable constant temperature.

I also decided that solar panels should be on the top of the design to power the electric systems of the habitat, which will be talked about later in this report.

On the third page are notes that I made for the dimensions of key parts of the design - for example, the bed. The bed needed to fit well inside the triangular bedroom module. The size of the main body depended on the size of this module.

I also included dimensions of the maximum size of a human that my design would be suited for.

Below that are some notes on potential materials that I could use. Aluminum and Stainless Steel were good options, as they are quite heat-resistant and lightweight. However, stainless steel is much more resistant overall (abrasively as well as in terms of heat resistance). At this stage I think it would be appropriate for there to be three layers to the walls. This is composed of an outer layer of stainless steel, followed by a middle layer of ceramic insulation material, which is followed by the last layer of aluminium on the inside. This provides multiple layers of heat resistance whilst balancing the weight of the design.

Below that are some sketches I made when designing on CAD to help get the dimensions correct.

Linked below are two projects that I used for inspiration during my ideation phase.

https://ofis.si/eng/projects/research/shelters_in_extreme_envronments.html

https://issuu.com/gsdharvard/docs/habitation_in_extreme_environments

The design of the habitat was also inspired by the Arabian traders of the Bedouin, who had dark tents made of goat fur, which was a rectangular piece of goat fur fabric which was supported at the center by a large pole. If the tent was large it was supported at the edges by more smaller poles. The walls of the tent could be raised when it was hot and lowered when it was cold or windy, which is similar to the Push-out extension rectangles which I have in my design, and similar to the smart closed loop foil blind auto adjuster which is covered later on in the smart features section.

In the winter the size of the tent was reduced to reduce the heating energy needed to heat the tent.

These smart yet simple features have inspired both mechanical and smart electronic features in my design. It’s always a good idea to gain inspiration and ideas from the people who have inhabited the desert for centuries, refining their way of living over time.

The desert is not only physically harsh but can also be emotionally harsh. It's very plain, and this can affect the mental health of the inhabitants over long periods of time. I also understand that when spending long amounts of time in a habitat, it becomes more and more important that the space is used efficiently, and that the layout is optimized.

First of all, before any of this is considered, the basic needs of a human need to be fulfilled. This can be seen in Maslow's hierarchy of needs. These needs include food, water, warmth, shelter, safety and security. This is prioritized and addressed in the design.

Next, other needs need to be met to ensure the habitat is not just a place to live but a place to thrive. I have researched sources reporting on space for this, as space is very similar to the desert from a psychological standpoint. They are both very plain and deserted, and you must spend almost all of your time indoors.

Jean-Francis Clervoy (a French engineer and astronaut) says that

The main psychological challenge of a mission is confinement, isolation, [and] crisis management.

Therefore, I have included many windows in my design to help open up the space. These have to be either double or triple-glazed to help insulate the habitat. The windows are also made out of polycarbonate due to its impact and heat resistance.

To help aid crisis management, I have included a meditation and observation pod at the top of the design. This gives a view of the vast desert or environment and can help reduce stress. It is also separated from the rest of the habitat.

This is something that has been ignored in many space programmes, as many of them have to verify that the astronauts are not claustrophobic or easily agitated.

Private spaces are often overlooked in emergency habitats or even in space stations. When multiple people share an already confined public space for long periods of time, conflicts can often arise. Private areas can not only be used to prevent this but can also be used to aid physical recovery if the habitat is deployed in a disaster zone. It can also be used simply to mentally recharge. The mental benefit outweighs the extra cost of production and the extra space needed, in my opinion. This can be very effective if the additional space is used efficiently or can be deployed (for example, a bedroom that folds away to reduce travel volume).

Although private spaces are needed, semi-private spaces are also needed for the community. This was requested by the crew of the HI-SEAS. I have included this in the form of the push-out boxes, which can serve as semi-private spaces as these sections are divided and separated from the main area.

S Hauplik-Muesburger (a researcher and architect in the extreme environment sector) said in 2021 that

In [extreme environments] you can't slam the door and come back later when you have calmed down. And this is why the architecture has to provide for space as well.

One public communal space is also needed. I was considering a roof deck with a ladder from the desert floor leading to the top so that the crew could watch the sunset in the evening. However, this could not be used during the day or night due to extreme temperatures. It also takes up valuable solar panel space. I instead decided that this space should be the community dining area.

Sheryl Bishop (a behavioural researcher in the extreme environment and space sectors) said that

Eating times are very important to be together.

Therefore, the community dining area that I have decided to include at the centre of the design should serve a purpose beyond simply eating, but also bonding between users.

But how do we know how far we should go to accommodate these needs?

J-F Clervoy (a former astronaut) said in 2021 that

All my missions were on board a space shuttle, and space shuttle missions are always short and very intense. You don’t have free time. But, when you fly six months, the weekends and more or less free and you can have activities like playing music, reading, writing,... drawing, taking photographs...

Therefore, it can be concluded that the level at which the habitat should accommodate these needs depends on the time spent there.

The number of inhabitants and length of the mission or stay should be directly proportional to the size and comfort of the habitat.

To add to this narrative, Sheryl Bishop said

Short-term missions are expeditionary missions, where the task is accompanied by an intense work schedule and often compared to a camping lifestyle, where minimum comfort is acceptable. Therefore, adapting to a certain environment is not an issue. But, long-term space missions, where people would be residing in hostile environments over an extended period of time, are completely different.

To aid comfort, it is very important that an inhabitant does not feel confined. This can be caused by a violation of space.

This can be measured by the minimum habitable volume of the space.

Christina Ciardullo (an architect and researcher) said

Minimum habitable volume is the volume left available to the crew after accounting for the volume taken up by deployed equipment, stowage, trash, and any other structural inefficiencies.

And to conclude my findings from this research that were implemented into my design, this quote sums it up nicely.

Dorin Prunariu (a Romanian Cosmonaut) said in 2020 that

It becomes increasingly more and more important for the astronauts, especially for astronauts who spend a long time in outer space, to have a nice environment, to have things organized, to relax the eyes and be relaxed when you look around, and to not only be stressed by the huge equipment and all those wires around.

I have embedded Fusion's 3D viewer here. The prototype design can be viewed there. In case you can't access it, follow this link: https://a360.co/3xAS16z

I find this particularly useful, as you can view and interact with the design in a way that screenshots cannot show. Dimensions and other details can be explored here. The design can also be seen through a cross-section or an explosion.

I designed this especially for prototyping. It is optimized for 3D printing, and the design is made of clear acrylic and PLA.

Each separate component is designed to slot into or onto the others to create a prototype model that does not need glue and can be assembled and disassembled by hand.

The 'Push-Out' boxes can slide in and out of the main body. When inserted, there is a small, slanted bump for them to travel over. This is positioned on the main body of the floor. After it passes this bump, it can not go backwards or back over it. It is therefore locked into position limits. There are also some tabs on the side of the box. These tabs prevent to box from overextending beyond the body and hold them in place. These two features ensure the box can be moved between the storage and deployed positions. There is a small handle at the top of the box for the user to move it around.

I have included some standard-scale objects in the design to represent a human. These are in the form of blocks.

I have also made some beds, oil drums, and a table to add to the atmosphere and to aid visualisation by providing a scale of well-known objects.

Tolerances were considered to ensure there would be enough space for some epoxy resin to be between the acrylic windows and the 3D PLA print, and so that each component would slot into the other smoothly.

The 'Tri Pods' or Triangular bedrooms can be pivoted about the joint. This allows the user to interact with the prototype to see what both the deployed and travel configurations look like.

In the center is the central spine hub. This will help support the roof in the real design. I was still unsure which orientation I wanted the central triangular hub to be in, so I made it pivotable so that I could try both configurations. It pivots about the center of the main body.

Each of the components need to be 3D printed. I used my school's Creality K1 printers to print these parts. I recommend using the quality preset on your printer’s slicer, as having small layers and layer lines will be useful when you are finishing the build.

Once the prints are done, they need to be removed carefully, as some of the parts are quite fragile.

The supports also need to be removed very carefully. This can be done using pliers. Every bit of support needs to be removed, as some of it could get trapped between components, which could lead to parts jamming together.

I sanded the parts with very low grit sand paper. I did this only around the areas where supports have been. If you are electroplating, then you should sand all areas.

The acrylic parts also need to be cut. I used my school's laser cutter. I used 3mm thick clear acrylic sheets to make my parts out of. The DXF files needed can be derived from the CAD design. Make sure to tessellate the triangles to reduce offcuts and stock material wastage.

If you would like to electroplate the parts, here are some resources:

Guide - https://www.gaterosplating.co.uk/plating-support

Electroplating (Making electrolyte) - https://www.youtube.com/watch?v=G-PtnwtOR24

Electroplating (Bought components) - https://www.youtube.com/watch?v=TlD9USAhcEs&t=240s

Alternatively, you can spray paint the parts. Using a filler primer before painting is recommended if your print has thick layer lines.

When applying the spray paint, you should be outside or in a well-ventilated area. Spray the part from around 15cm away. Multiple coats should be applied. Areas which are not to be painted should be covered with removable tape.

Remember to wait for the paint to dry before touching the parts as this can affect the finish.

I used black lacquer paint for the black parts and used chrome spray paint for the silver parts.

I painted the parts rather than electroplating due to the huge difference in equipment cost.

Once The parts are printed, cut and painted, the acrylic windows need to be added.

This can be done using epoxy resin. This should be done in a well-ventilated area. Mix the two components of the resin together and coat the edge of the acrylic. Then slot the acrylic into its slot on the 3D print.

Make sure to rest the print and acrylic on an object so that they are still aligned while they are bonding.

Ensure that the resin is touching nothing apart from the acrylic and print.

More resin can be added to the edges at this point.

Some of the resin got a bit messy with my prototype. If I were to make this prototype again, I would enlarge the acrylic windows so that they were larger than the window slot on the 3D print. This way, the resin could be added onto the overlap and the resin would be hidden, leaving a cleaner finish. The oversized acrylic could be put into an indented slot around the frame so that it would still be in the correct position.

For the meditation pod, I simply taped the acrylic in place as using resin here would be too complicated and messy.

Once the acrylic and PLA have bonded, the prototype can be assembled. If you are unsure of how to assemble it, then reference the 3D design provided earlier. You can hover over each part to see what component it is. You can also explode the design to see how it is assembled.

When testing the prototype, I decided to go with the first orientation of the central spine storage hub as it provides more usable space overall. This orientation created three separate pockets of space that were usable, whereas the other orientation gave no usable large spaces and gave long corridors between each corner. It's more efficient to have it in the first orientation.

This was also the first visualization I had of the design. I was able to switch between the travel and deployed states. I found it to function well, however the hinges whilst they did not break, were quite fragile. I shall ensure the hinges are strengthened in the final design.

I am quite pleased with how the prototype turned out; with the only thing I would change being the way the acrylic was bonded to the PLA print. 

I was satisfied with the size of the deployed position compared to the travel position and found the geometry appropriate for all the components.

I shall take most of the geometry to the final design.

Once again, I have embedded the design using Fusion online viewer. If you, for some reason cannot access this then follow this link: https://a360.co/4cnIYF0

You will notice that the final design is significantly more refined and developed that the previous prototype. I shall analyse and explain each of the features.

I encourage interaction with this design in the viewer. You can explode the design, explore the design and view individual components to help better understand the design.

The central hub has been divided into two sections after the prototype. It consists of an upper and a lower section. I decided to use the top of the lower section as the eating table. This was important for the community aspect as explained in the research section. This central space ensures everybody can eat together.

A metal tube supports the upper layer above the lower layer. This was later developed further in the stress testing section. Each layer consists of two shelves for storage. The shelves are split into three sections. As it is triangular there are three sides to the component. There are doors on each side with ergonomic handles. The doors on the lower layer opens down and the doors on the upper layer open upwards.

As there is to be stairs running up to the meditation pod, the stairs needed to be redesigned considering the new gap between layers. The steps on the doors and shelves remain there. I attached the remaining ones to a series of three metal beams attached at a hinge on the upper layer. This was done so that it could fold upwards when not in use so that it would not be present at the table. However, in order for the stairs to fold upwards correctly, they need to avoid the already present steps on the upper layer. I therefore designed the metal beams that make up the ladder to avoid the existing stairs. In order for it to close fully, the steps attached to the ladder needed to pass through the door and upper layer in the areas which they intersect. These intersections were made and covers were designed to ensure that there were no open gaps to keep the contents inside the shelf protected.

A development of the sliding doors was added between the bedroom and the main area. The sliding doors move linearly along some grooves and the door itself has a part on the top and bottom which slides into the groove. These doors are on both the bedroom and main area walls. This is due to it not being guaranteed that both these walls will be connected, as they will not be in the travel configuration, and it is important the inside it kept protected. The door does not have a handle but instead an indent for the user to push on. This is due to handle blocking the sliding and there not being enough space for one between the walls of the Tri pod and the main area. The lower groove is in the floor of the Tri pod and the main area. The upper groove is extended and attached to the wall above the door for both locations. This wider door can be used to transport larger goods and items into the habitat before it is deployed, as then these doors will not be usable from outside to inside but from main area to Tri pod.

An LED lighting strip has been added around the edge of the roof. It has been positioned here to aid lighting and ease of use of the Main area. An LED triangle has been added to the lower area of the upper layer, which is above the central table. This provided lighting for the entire table. The LED strip is covered by a diffusing light cover to ensure eyes are not hurt and that the light is spread.

Solar panels have been added to the roof of the design These cover a significant amount of the total surface area of the roof. This will provide electricity as outlined in the Electronics and smart systems section. Toroidal propellers have also been added below the meditation pod. These will harvest energy from the desert winds. This is also expanded upon in the Electronics and smart systems section. A plate divider has been added between the propellers and the meditation pod so as to not distract the pod user. It also works to disperse and redirect some used wind, as well as direct new wind into the propellers.

A vent has been added to exhaust hot air built up in the design. The hot air from the pod and the main area itself should rise upwards to the top of the pod. This hot air will travel up the chutes and directed outwards. It is very important that sand is not able to enter the design from these chutes. That is why there are three of them as opposed to one larger one, to decrease the chance of a sand particle entering. They are also vertical to ensure sand particles blown by the wind can not enter through the chutes. The top of the chutes also have guards on them to stop debris travelling down the chutes. This was inspired by snorkel guards. To ensure as much of the hot air is flowing out as possible, the beginning of the chute inside starts wide, but tends towards the shape at the top.

The tabs on the side walls of the push out boxes remain the same. Instead of there being a slanted piece on the floor to stop the box coming too far inwards, There are instead slots in the floor and corresponding slots on the bottom of the floor of the push out. These slots limit the movement of the push out box to ensure it doesn’t slide too far inwards. The push out needs support from underneath or it will fracture when deployed. To solve this, I have integrated the outer section of flooring from the main area floor into the push out. This supports it when it is deployed and in normal use. This eliminates instability and flexing.

The bed is much more developed than the simple experimental on used in the prototype. The design is no longer narrowing towards the end of the bed. The comfort trade off with space was too little to be taken forward. The bed now has storage space underneath it. It is held up from below by two support structures on each end. It has been optimized to take the load at the middle point of the top whilst taking up as little space as possible and saving materials. The design could be injection moulded out of a very tough and structurally rigid material such as HIPS. If the bed were to be made of HIPS with an internal structure pattern, not all of the side space would be needed for the support of the bed. Therefore, the design has a cutout in the side supports to reduce material and weight.

It is very important that all the needs of daily life are met in a habitat. If there are a few features that help the inhabitants to thrive or have extra comforting or useful features, yet the habitat does not meet the basic daily needs of the inhabitants, then that is not good enough. The basic needs must be met first. I made sure to design the habitat with these features in mind before adding extra features that improve the quality of life. The toilet is in the bathroom section of the Tri pod. There was not enough space for a proper toilet system with functioning flushing and waste disposal, so I made the decision to use the pit toilet. Beneath the toilet will be a deep sand pit. After each use, the pit of the hole should be covered with sand to stop the smells reaching the surroundings or the Tri pod itself. It is always important to consider the surroundings of the habitat when designing it. The toilet is designed like to look like an ordinary toilet. It drops straight down to the ground. The toilet will have a removable cover on it. This is so that the seat can be removed and thoroughly cleaned or replaced. The cover will be fastened on using a lever locking mechanism, similar to the one used on glass jars. The area in contact with the toilet seat will be covered in a 5mm thick sheet of silicone. These two design decisions are to ensure that the seat does not get blown up by strong winds during sandstorms, and that no wind or sand can escape through the gaps.

The curtain of the bathroom was made from a canvas fabric, which is inspired by and based off the canvas tents that the Bedouin tribe used. It efficiently and effectively insulates the bathroom and reflects heat. This curtain can be opened or closed along the pole to which it is attached. Canvas is also often used in sails, or outdoor covers, meaning it is resistant to moisture and is chemically resistant. It also dries off effectively and quickly, meaning that it will not deteriorate. Canvas is also very resistant to wear and torsion, meaning that it will not easily rip, increasing the longevity of the curtain. The reason I did not use reflective foil similarly to the window covers it because if the window covers are open, then the sunlight could potentially reflect off the curtain and disrupt the comfort of the users of the Tri pod by damaging their eyes and causing annoyance.

The shelves are located in the bathroom section of the Tri pod. This utilizes space that would not have otherwise been used, due to the narrow nature of the Tri pod tending towards the corner. The shelves are for storing bathroom supplies and equipment, and is away from the spray of the shower, keeping the storage contents dry.

Collecting and using water is especially important in a desert environment, and it is important that the process is efficient. The water is collected from rain landing on the slanted roof of the Tri Pods, provided rain is present which is rare yet possible, especially in the winter. This water is directed towards the gutter system. The gutter directs the water through the roof and wall of the Tri pod and stores it inside a plastic container, located in the top shelf in the bathroom section. This water is stored inside to prevent it evaporating. When the shower is needed to be used, the user can pull a water gate between the shower dispenser and the water storage. The extent to which the gate is opened can control the water flow to the user’s liking. When the gate is open, the water flows from the container to the dispenser, where it is sprinkled upon the user by the small water outlets on the water dispenser. The water is heated slightly during the day by the container being in contact with the roof of the Tri pod. This enough is enough to heat but not evaporate it due to the positioning of the water container inlet and the surface area of the water container in contact with the tri roof. The insulator can be removed here to enhance the heating effect, and the water container can be removed to stop cooling in the night, with the contact area effectively functioning as a cold plate cooling pad.

For changing the habitat between deployed and transport mode, the users need fold in the Tri pods. This can not be done without a handle due to the nature of the heated shell and shape of the shell. Therefore, a handle has been attached to the end of the Tri pod. This gives the user maximum torque to close the Tri pod, which makes it easier. The handle can be coated with a rubber heat insulator to stop the user’s hands being burnt when in use.

When the habitat is in the deployed mode, the inhabitants need a way to get from inside the habitat to outside. This is no longer possible from the main area door as it no longer can open to outside when it is deployed. Instead, there is a door from the side of the Tri pod to the outside. This can be accessed when the Push out box is slid inwards. This adds another layer of security to the habitat, as the doors can only be opened from the inside now and are concealed. The detailed reasoning for this is in the Psychology section. This door has a hinge as opposed to the sliding door mechanism of the Main area door. This is due to the door interfering with the room if it was a sliding door. It is also easier to lock if it is a hinge door. The door can be opened from pushing on the outside and the opposite in the inside. This configuration means that there is no handle on the outside of the door. This ensures that the handle on the door does not interfere with the push out box and the door is less visible from outside.

As the habitat needs to be transported easily, it needs to have multiple transportation solutions. The first of these solutions is by helicopter. This can not be done by hooks as the strain on them would be high. The habitat instead needs to be lifted up from the floor, as this would distribute pressure more evenly and would stabilise the habitat under helicopter lifting. This would also eliminate fractures. Therefore, the product has three wide strap buckles on the main floor. The straps from the helicopter go through the loops on the buckles and this is how the habitat can be safely lifted. The straps would also pass under the Tri pod floor to both support it and hold it in place.

The legs on the floor of the habitat self-adjust to level the habitat floor. This is explained in the Electronics systems section. The base of the leg which is attached to the floor is aluminium with a black oxide coating to prevent corrosion and abrasion wear from contact with the ground. The leg in contact with the ground is made of cast iron, which is very resistant to abrasion. Although Iron is very vulnerable to rusting, there is little to salt content in the air in the desert, so rusting and corrosion will not be a problem. Other materials can be used for other environments, as this is a simple part and can easily be replaced.

The habitat has wheels on the base for it to be easily transported by car. Beaching is common in the desert or in sandy areas. Therefore, are four wheels to distribute the pressure evenly and the wheels are thicker than usual. The wheels also have horizontal grooves on them to enhance the grip on the sand. The rims of the wheels have cutout sections to make them easier to rotate and to reduce the weight of the rims. The wheels can be folded inwards about the joint at the base. The base joint has been blended into the base plate to strengthen the joint. The wheel rotates about the axel attached to the fold out module which is connected to the base joint.

The habitat has a tow bar attached to one of the corners of the main floor to allow for easy towing by a car. The tow bar rotates about a joint on the base plate so that a natural angle of towing between the towing rope and the horizontal can be reached. This reduces strain on the tow bar. The rope can be tied around the bar on the end of the part. The rope can be tied around the back tow bar of the car to tow the habitat.

Here are some examples of manufacturing methods that could be used to create the most common parts.

The metal panels could be made from router or milling machine cut stock sheets of metal.

The more complex metal parts such as the hinges, strap loops and tow bar could be metal cast or formed from stock using a milling machine.

The smaller plastic parts could be 3D printed. If the habitat were mass manufactured, then the parts could be injection moulded.

The water container and water collection pipes can be rotation moulded from a polymer.

The polycarbonate windows could be laser cut in parts from stock material.

The parts in the leg could be made from a stock rod using turning.

Metal sheets or plates with their edges touching can be MIG or TIG welded depending on the material. MIG is recommended for the main metal plates (stainless steel and aluminum)

Smaller parts can be brazed to create a cleaner finish.

Metal sheets on top of each other can be spot welded.

Nuts and bolts will also be commonly used in this design.

There are a number of electronics systems integrated into the design. As highlighted in the introduction, the habitat is designed to work with the environment.

The first of the features are a line of toroidal propellers just below the meditation and observation pod. These propellers harvest energy from the winds in the open deserts which can be used to power the electronic systems inside the habitat and also the smart adaptive systems.

Toroidal propellers are used instead of ordinary propellers as toroidal propellers have a weaker and smoother vortex created off the leading edge of the propeller blade. This creates significantly less noise. This is extremely important as this means that there is no noise pollution inside or outside of the habitat. It also reduces vibrations and is more efficient than ordinary propellers as a medium speed.

The second smart feature of the habitat is smart blinds. These blinds help to regulate the temperature inside by automatically adjusting themselves based of temperature data from inside each section of the habitat. For example, if it is too cold inside a certain section and the sun is still up, the blinds would be lowered slightly to heat up the room. The blinds would be raised if the temperature exceeds the pre-determined value. This can be overridden by any user at any time.

The third smart feature of the habitat is automatic levelling legs. These legs are extendable and retractable. Gyroscopes would be fitted at points directly above the legs on the base. The gyroscope data will be compiled and analysed to calculate how the entire habitat can be levelled with the least motion possible. For example, if one side were too high and the other too low, the higher side would be shifted downwards by the same amount that the lower side is shifted upwards provided they both have the same distance from the centre. This is important as sand in the desert can be uneven due to the strong winds. The habitat needs to be level to be comfortable and this feature eliminates the need for the users to choose a level area for the habitat to be placed, which increases the number of possible placements or deployable positions in a certain area.

Solar panels are fitted to the roof to extract energy from the intense sun in the desert. This is a major source of power but only works during the day, so a battery would need to be charged when power output from the solar panels is in excess compared to the requirements of the system during the day.

I decided to run some stress tests on areas which may be vulnerable to load. The two areas I decided to test are the central storage hub and the hinge between the 'Tri hinge' and the main body. 

The purpose of this stress test is to help optimize the design of the central hub. I shall compare the results of this stress test to an alternative design to see if it is an improvement.

I applied a load of 2000N to the top shelf of the central storage hub. This was to simulate storage being held there as well as a user climbing up the stairs to the meditation hub.

The simulations showed significant stress towards the core if the hub, and significant displacement on the outer edges between the corners.

The area with the highest level of stress was the column between the top and lower layer.

To fix this I plan to reinforce the areas with high displacement and add more columns in strategic places to reduce the stress on the central support column.

On the improved design I added three more columns in the corners as these areas were vulnerable. They were not receiving support from the shelving system grid inside the upper and lower layers.

Adding a column in their areas should significantly reduce the stress and load on the central column. These new columns will also be able to cope with a higher load than any other position, due to the support from the corners of the design.

To support the areas with high displacement as seen before, I added some supports extending from the top of the column to the middle of the outer portion of the upper shelf. This should distribute some of the load to the three corner column supports and should reduce flexing.

The simulation load settings are exactly the same as before. The results showed that the design changes had been a success. All of the stress from the central part had been reduced significantly, with yellow portions eliminated. The load on the columns has now been distributed evenly and therefore the total stress on the central column has been relieved.

The new supports from the corner columns to the centre of the upper edge show very little stress, indicating that these new structures can handle the load well. This is reflected in the displacement simulation, with red and orange areas eliminated and a visual decrease in flexing under the same load.

I am pleased with the new design changes. The components now function as intended and have a reliable load capacity.

The second component I wanted to optimize, and test are the hinges. I first noticed that this needed to be addressed when testing the prototype. This was under simple functional loads.

I decided to run a simulation on the current design to see if the result was sufficient. I had already tried to optimise and strengthen the hinge after the prototype test.

I applied a load of 3000N to the floor of the Tri pod. This is representative of ordinary loads. In the final design the Tri pod had a supporting leg underneath it, however I removed this for the purpose for the simulation to get a better understanding of the system.

After the simulation run, the most amount of stress was seen in the hinge area. However it was a very little amount of stress, this could be reduced this is one of the most important and used joints in the entire design.

The design was flexing towards the end of the floor as the flexing in this part was amplified by the principle of moments.

The stress level in the hinge area decreased slightly, showing that the new design was better but only slightly better than the first design. This was a significant improvement from the prototype hinge.

The flexing towards the end of the base plate remained the same, however flexing was localized to the end of the plate as before. The only way to reduce this would be to add a large rib along the base attached to the walls. This would significantly affect the usability of the component. 

The leg underneath the flexing end should be enough to stop fractures. This issue is not possible to be reduced directly from the hinge.

I can conclude that the part is safe to use.

Here are some renders which I produced in Fusion. I think they really bring the design alive. I have rendered in an orange background to make the design clearer and more visible. I have also rendered some images with the ‘Dry Lake Bed’ environment in Fusion, which are attached below this step.

Note for transparency: Every single part in this design was designed from scratch by me in Fusion, except the propellers which were imported from online.

I would like to thank Autodesk and Instructables for providing this incredible opportunity. I really hope you like my design.

I tried to think outside the box as much as possible when designing this habitat. I became very passionate about this project, as I do with most of mine, and I really enjoyed it, which I think was key.

I learnt a lot in the process of designing this product, and that’s what designing is all about – applying current knowledge and acquiring new knowledge to design something that will change the world for the better.

Thank you.