Factory Production

TL;DR

  • Concept: Self-replicating factory builds copies of itself from local resources
  • Two types: Factory-Replicator (F-R: robots + domes + equipment) and Factory-Mirrors (F-M: mirrors)
  • Lean manufacturing: Storage outside (vacuum), only JIT buffer inside
  • Output: Self-replication 1 -> ~1,650 factories in ~4 years (bottleneck: “Vitamins” delivery)
  • Size: Dome ~1,500 m^2 (~50x30 m), height 6-8 m, atmosphere 0.1 atm O2
  • Materials: 600 t regolith/day -> 42 t Al + ~11 t Fe-Mn steel + 25 t Si
NotePurpose and Calculation Status

The purpose of this documentation is to confirm the fundamental feasibility of the project and provide preliminary estimates of budgets and timelines. Calculations confirm: all necessary technologies exist (MRE electrolysis, WAAM, solar concentration, electromagnetic launch), materials on Mercury are present in sufficient quantities (Al, Fe, Si, Ti, S), delivery logistics are realistic given current launch cost trends.

All figures provided (areas, capacities, material flows) are preliminary order-of-magnitude estimates. Transition to implementation requires work by a professional engineering team to refine parameters, detailed design, and validation of adopted solutions.

Self-Replication Concept

The “Ground Zero Factory” is the first self-replicating factory on Mercury. Its task is to build new factories from local materials using robots and solar energy.

Parameter Value
Principle Gravity-flow line + vacuum distillation
External environment Vacuum
Internal dome environment Oxygen 0.1 atm (local, from MRE)
Dome dimensions ~50x30 m (~1,500 m^2)
Dome height 6-8 m (for 1 t bridge crane)
Power consumption (factory) ~124 MW (114 MW elec. + 10 MW thermal)
Available energy (CPV system ~10.5 t) ~151 MW (~27 MW reserve without Mass Driver)

Exponential growth strategy:

Factory #0 (Ground Zero) -> builds Factory #1
Factories #0-1 -> build Factories #2-3
Factories #0-3 -> build Factories #4-7
...
-> 1 factory -> ~1,650 factories in ~4 years (practically, due to "Vitamins" delivery)

First expedition: ~72 tons from Earth (including ~10.5 t CPV system), assembly in 7 days.

More on preparation: First Factory Assembly (Bootstrap) | Roadmap

Factory Types

All factories use the same dome (50x30 m, 1,500 m^2) but differ in assembly zone specialization. Combining robot, dome, and mirror production in one dome is impossible - insufficient floor space.

Lean Manufacturing Principle

Inside the dome - only equipment and operational buffer. Material and finished product storage - outside on open pads (vacuum, no corrosion). Crab-M robots load/unload through the airlock using JIT (just-in-time) principle.

Parameter Inside dome Outside (vacuum)
Purpose Production Storage
Area 1,500 m^2 (dome) ~500 m^2 (pads)
Contents Machines, conveyors, AGV Racks, containers
Buffer ~50 m^2 (airlock) Unlimited

Factory-Replicator (F-R)

The first factory (“Ground Zero”) and ~150 subsequent ones (~10%). Fully self-sufficient for building new factories:

  • Gen-2 robots (Mole-M, Crab-M, Centaur-M)
  • Domes (cutting, welding, sealing)
  • Factory equipment (CCM, rolling mills, WAAM cells)
  • Mass Driver elements (rails, coils, frame)
  • Does NOT produce mirrors

F-R Layout

flowchart TD
    subgraph EXTERNAL["External Contour (vacuum)"]
        MHD[/"MHD inlet<br/>melt 1500C"/]
        LOCK["Airlock<br/>JIT supply"]
        STORAGE["External storage<br/>racks + containers"]
    end

    subgraph DOME["F-R Dome (0.1 atm O2, +25C)"]
        subgraph CASTING["Casting (200 m2)"]
            TUNDISH["Tundish"]
            MNLZ_AL["CCM-Al"]
            MNLZ_FE["CCM-Fe"]
        end

        subgraph ROLLING["Rolling (200 m2)"]
            FURNACE["Reheating furnace"]
            MILL["Rolling mill<br/>6 stands"]
        end

        subgraph WIREDRAW["Wire drawing (100 m2)"]
            WIRE["Wire drawing mill<br/>dia 1.6 mm"]
        end

        subgraph FORMING["Forming (200 m2)"]
            WAAM["WAAM 3D printing"]
            GRIND["Grinding cell"]
        end

        subgraph ROBOTS["Robot assembly (250 m2)"]
            STAP_R["Robot assembly jig"]
            TEST_R["Testing"]
        end

        subgraph DOMES["Cutting + dome welding (200 m2)"]
            CUT["Cutting table<br/>10x5 m, laser"]
            WELD["Ultrasonic<br/>panel welding"]
        end

        subgraph EQUIP["Equipment assembly (200 m2)"]
            STAP_E["Equipment assembly jig"]
        end

        BUFFER["Airlock buffer<br/>50 m2"]
    end

    MHD --> TUNDISH
    TUNDISH --> MNLZ_AL & MNLZ_FE
    MNLZ_FE --> FURNACE --> MILL
    MILL --> WIRE --> WAAM --> GRIND
    GRIND --> STAP_R & STAP_E
    LOCK --> BUFFER
    BUFFER --> CUT --> WELD
    STAP_R --> TEST_R --> LOCK
    STORAGE --- LOCK

F-R Zones

Zone Area Purpose
Casting ~200 m^2 CCM-Al + CCM-Fe
Rolling ~200 m^2 Profiles, sheets, wire
Wire drawing ~100 m^2 Wire dia 1.6 mm for WAAM
Forming (WAAM + grinding) ~200 m^2 Robot parts, equipment, MD
Robot assembly ~250 m^2 Robot jig + testing
Cutting + dome welding ~200 m^2 Table 10x5 m + ultrasonic welding
Equipment assembly ~200 m^2 Factory equipment jig
Airlock buffer ~50 m^2 JIT supply from Crabs, output
Passages ~100 m^2 AGV, 1 t bridge crane
TOTAL ~1,500 m^2

Factory-Mirrors (F-M)

The majority of factories (~90%). Produces mirrors for solar concentrators and Mass Driver:

F-M Layout

flowchart TD
    subgraph EXTERNAL["External Contour (vacuum)"]
        MHD[/"MHD inlet<br/>Al melt"/]
        LOCK["Airlock<br/>container output"]
        STORAGE["External storage<br/>mirror containers"]
    end

    subgraph DOME["F-M Dome (0.1 atm O2, +25C)"]
        subgraph CASTING["Casting (200 m2)"]
            TUNDISH["Tundish"]
            MNLZ["CCM-Al"]
        end

        subgraph FOIL["Foil rolling (300 m2)"]
            ROLL_F["Foil rolling mill"]
            ANNEAL["Foil annealing"]
        end

        subgraph ASSEMBLY["Mirror assembly (600 m2)"]
            ZFOLD["Z-fold conveyor"]
            TENSION["Cable tensioning"]
            ELECTRO["Control electronics"]
        end

        subgraph QC["QC + packaging (200 m2)"]
            TEST["Test stands"]
            PACK["Containerization"]
        end

        BUFFER["Airlock buffer<br/>50 m2"]
    end

    MHD --> TUNDISH --> MNLZ
    MNLZ --> ROLL_F --> ANNEAL
    ANNEAL --> ZFOLD --> TENSION --> ELECTRO
    ELECTRO --> TEST --> PACK --> BUFFER --> LOCK
    LOCK --> STORAGE

F-M Zones

Zone Area Purpose
Casting ~200 m^2 CCM-Al (aluminum only)
Foil rolling ~300 m^2 4 micron foil for mirrors
Mirror assembly ~600 m^2 Z-fold conveyor, ~350 pcs/day
QC + packaging ~200 m^2 Test stands, folding, containerization
Airlock buffer ~50 m^2 Container output to Crabs
Passages ~150 m^2 AGV, conveyor lines
TOTAL ~1,500 m^2

Inter-Factory Logistics (Crab-M)

Factory specialization requires transport between them:

From To Cargo Transport
F-R New factory site Dome (8 t, folded) 4 Crab-M
F-R New factory Equipment (~51 t) 6 Crab-M
F-R MD site Rails, coils, frame 4 Crab-M
F-M Mass Driver buffer Mirror containers 4 Crab-M
F-R All factories Finished robots Self-propelled

Intra-shop logistics (inside dome): AGV (automated guided vehicles) + 1 t bridge crane + Centaur-M (manipulators on assembly).

Three Stages of Factory Production

Factory production is divided into three sequential stages:

1. Material Processing (Regolith -> Al/Fe/Si)

All regolith processing occurs in the common material base of the project.

Process: - Regolith crushing - Melting in solar furnaces - MRE electrolysis -> separation into Fe, Al, Si, Ti, S - Distillation -> aluminum purification - Material transport to factory dome

More details: Regolith Processing

Material output (600 t regolith/day):

Material Output Application
Aluminum (Al) 42 t/day Mirrors, robot casings, conductors
Iron (Fe-Mn steel) ~11 t/day Robot frames, MD rails, dome frame
Silicon (Si) 25 t/day Solar panels, fiberglass
Titanium Dioxide (TiO₂) 3 t/day Mirror electrochromics
Sulfur (S) 18 t/day NaS batteries

2. Element Production (Materials -> Parts)

Finished materials (Al/Fe/Si) are transformed into structural elements: sheets, profiles, wire, parts.

Material Transport to Dome

Materials enter the factory dome through various transport systems:

Material Source Transport Destination
Al melt 42 t/day Distillation MHD inlet 1500C Aluminum line
Fe/Si melt 35 t/day MRE electrolysis MHD inlet 1500C Iron line
TiO2 powder 3 t/day Titanium line Pneumatic transport Electrochromics
Fiberglass 28 t/day Fiberglass line Conveyor (spools) Composite domes

Element Production Lines

Four production lines operate inside the factory dome:

More on each line:

Element output:

Element Material Capacity Application
Aluminum foil Al ~12 t/day Mirrors
Aluminum sheets Al ~15 t/day Casings, domes
Aluminum wire Al ~10 t/day WAAM, windings
Iron wire Fe ~8 t/day WAAM, cables
Iron rolled stock Fe ~10 t/day Frames, rails

3. Final Assembly (Elements -> Products)

Elements are assembled into finished products. Product type depends on factory specialization.

F-R: Replication (domes + equipment + robots)

  • Domes - silicate shell for new factories -> More details
  • Equipment - CCM, rolling mill, WAAM cells -> More details
  • Robots - Mole-M, Crab-M, Centaur-M -> More details
  • Self-replication - new factory construction coordination -> More details

F-M: Mirrors (~350/day)

  • Mirrors - Z-fold solar reflectors for Mass Driver

Material Flows

flowchart TD
    subgraph MATERIALS["REGOLITH PROCESSING"]
        REG["Regolith<br/>600 t/day"]
        MRE["MRE electrolysis"]
        DIST["Distillation"]
    end

    subgraph ELEMENTS["ELEMENT PRODUCTION"]
        MELT["Melting"]
        CAST["CCM casting"]
        ROLL["Rolling"]
        WAAM["WAAM"]
    end

    subgraph ASSEMBLY["FINAL ASSEMBLY"]
        DOME["Domes"]
        EQUIP["Equipment"]
        REPLI["Self-replication"]
    end

    REG --> MRE
    REG --> DIST
    MRE --> MELT
    DIST --> MELT
    MELT --> CAST
    CAST --> ROLL
    ROLL --> WAAM
    WAAM --> DOME
    WAAM --> EQUIP
    DOME --> REPLI
    EQUIP --> REPLI

    style MATERIALS fill:#fff3cd
    style ELEMENTS fill:#d4edda
    style ASSEMBLY fill:#cce5ff

Energy Consumption

Energy is divided into thermal (solar concentrators) and electrical (photovoltaic panels):

Thermal energy (solar concentrators):

Consumer F-R F-M
Solar furnaces (regolith melting, MRE) 10 MW(t) 10 MW(t)

Electrical energy (GaAs panels):

Consumer F-R F-M
MRE electrolysis (60 cells × 1.8 MW) 108 MW 108 MW
Rolling mill / foil 2 MW 3 MW
WAAM + grinding 0.05 MW -
Assembly jigs 0.5 MW -
Cutting + dome welding 0.02 MW -
Mirror assembly - 0.5 MW
Robots (~50 pcs x 5 kW) 0.3 MW 0.3 MW
Control systems 2 MW 2 MW
Electrical TOTAL ~114 MW(e) ~114 MW(e)

Note: Solar furnaces use concentrated sunlight directly (no electricity conversion). At ~9.3 kW/m² solar flux on Mercury, a ~1000 m² concentrator provides ~10 MW thermal. MRE electrolysis is the dominant electrical consumer (~108 MW, Faraday’s law justification). Electrical consumers are powered by GaAs photovoltaic panels.

Available electrical energy: ~151 MW (CPV system ~10.5 t: Kapton+Al concentrators + GaAs cells)

Reserve over factory (without Mass Driver): ~27 MW. Mass Driver (~39 MW) starts after local Si panel deployment provides additional power.

More details: Production

References: Autonomous Manufacturing

Tip“Dark factory” technologies - industrial reality

Fully automated production without humans (lights-off manufacturing) operates at industrial scale:

Company Achievement Year
FANUC (Japan) Robots build robots, 50 pcs/day, 30 days without humans since 2001
Xiaomi (China) 81,000 m^2, 10M smartphones/year, 24/7 2023
Foxconn (China) 60,000 robots, transition to full automation 2024
Philips (Netherlands) 128 robots, 9 people on supervision 2020
Semiconductors (global) 300mm wafer fabs - fully automated since 2000s

Market: $119B (2024), CAGR 8.7%.

Applicability to project: A factory on Mercury is a lights-off facility with MRE electrolysis added at the input. All in-shop operations (casting, rolling, WAAM, assembly) have direct terrestrial analogs.

More details: Technologies and Sources

See Also