What is ZOTEK F30

ZOTEK F30 is a high-performance fluoropolymer foam made from polyvinylidene fluoride (PVDF).
It combines low density, chemical resistance, radiation stability, and exceptional thermal insulation, making it ideal for use in spacecraft, satellites, and launch systems.
On Earth, ZOTEK is used for cryogenic insulation, aircraft interiors, and high-end industrial packaging.
During lunar missions, this same material appears as protective packaging, vibration dampers, or thermal liners — meaning there will naturally be large volumes of it available as “waste” after delivery and unpacking of cargo.

The LunaForm 3000 system allows this material to be recycled directly on the lunar surface, turning mission waste into a valuable construction resource.

How LunaForm 3000 works

The unit operates as a dual-chamber thermal compression system, optimized for low-gravity and low-pressure environments.
Waste ZOTEK F30 foam is inserted into the top chamber, where it is heated and compressed using controlled temperature and pressure cycles.
Once the material reaches its transition phase, it is molded into 180 × 180 × 20 mm panels inside precision-machined cavities.
The lower chamber cools the new panels while the upper one begins a new cycle — enabling continuous operation.

The process requires no water, no chemical additives, and uses only ~1.8 kWh per cycle, achieving over 99 % material efficiency.
All emissions and particles are captured by a sealed filtration system, ensuring compatibility with lunar habitat safety requirements.

Output and capabilities

Each cycle yields a structural panel with interlocking edges, allowing panels to be joined together into large, lightweight structures without tools.
These panels are mechanically stable, non-flammable, and radiation-resistant, making them suitable for:

• Interior walls and floors of lunar bases,

• Thermal and micrometeoroid shielding,

• Storage modules and protective containers,

• Or even temporary shelters and landing site enclosures.

The modular design also supports on-site customization — the system can produce panels with embedded channels or connectors for wiring, air circulation, or monitoring sensors.

Applications in future missions

LunaForm 3000 is relevant for multiple mission profiles:

• Artemis Base Camp – recycling packaging and insulation from supply missions into usable construction material.

• Gateway logistics modules – processing waste foam from orbital cargo deliveries.

• Private lunar habitats – providing autonomous recycling for long-duration surface missions.

• Mars transit and surface outposts – enabling in-situ resource reuse to minimize mass resupply from Earth.

By turning existing waste into durable materials, LunaForm 3000 supports closed-loop life-support ecosystems and reduces mission cost and payload mass — both key factors for sustainable extraterrestrial operations.

Dual-use potential on Earth

Beyond space applications, the same system can be used for sustainable recycling on Earth, especially in:

• Remote research stations, disaster-relief zones, or military operations,

• Aerospace and automotive manufacturing plants handling fluoropolymer waste,

• Or circular-economy pilot projects focused on low-energy material reuse.

Because LunaForm 3000 works without water or chemical agents, it is ideal for areas with limited resources or where environmental impact must be minimal.

Summary

LunaForm 3000 is a self-contained, intelligent recycling unit capable of transforming advanced aerospace foam waste into strong, reusable building materials.
Designed for lunar conditions and validated through NASA’s LunarRecycle Challenge, where it won both the Digital Twin and Prototype awards, it demonstrates how future missions can build sustainable habitats from their own discarded materials —
a vital step toward permanent human presence beyond Earth.