January – May 2026
Undergrad Capstone
Objective: Engineer a 1:25 scale Lunar Tunnel Boring Machine
Development of a functional prototype to analyze mechanical excavation efficiency and kinematic mobility within high-fidelity simulated extraterrestrial environments.
FINAl Model
Design Team
About the Team & Project
This research initiative is a Senior Design capstone project for MCET 565 at the Rochester Institute of Technology (RIT). Our work focuses on bridging the gap between theoretical lunar physics and the practical constraints of autonomous excavation machinery.
The LTBM development process has allowed us to tackle complex engineering challenges, from thermal regulation in vacuum to abrasive regolith management. We are incredibly excited about the future of Lunar Tunnel Boring Machine (LTBM) research and development as a cornerstone of human lunar presence.
Anna DeJohn
Mechanical Engineer
Damian Hacke
Robotics & Manufacturing Engineer
Tess Libby
Mechanical Engineer
Dereck Rodriguez
Mechatronics Engineer
Isaak Rubis
Jun Han Bae
Mechanical Engineer
Project Sponsor (MCET 565)
Phase I: Concept Feasibility
The month was dedicated to technical benchmarking of conventional Tunnel Boring Machine (TBM) mechanics to extract baseline torque and thrust requirements. This was horizontalized with deep-dive research into lunar regolith mechanics and vacuum environmental constraints, identifying critical thermal hazards and material abrasiveness limits.
Following a team-wide ideation cycle, several design proposals were generated. These were evaluated using a weighted Pugh Matrix to compare performance across power efficiency, mass volume, and mechanical redundancy. This rigorous selection process finalized our modular architecture for the upcoming 1:25 scale prototyping phase.
Phase II: Detailed Design & De-Risking
February focused on systematic de-risking through project planning and the synthesis of preliminary 3D CAD models. Computational analysis was leveraged for motor selection and geotechnical load characterization, while the initiation of the formal drawing package ensured architectural consistency. Systemic risks were mitigated using a comprehensive DFMEA to isolate lunar failure modes and interface dependencies.
Controls and electrical system design maturity enabled the triggers for procurement, with the first ordering cycle for structural materials and components completed. Feasibility verification was solidified through the 3D printing of core sub-assemblies, confirming mechanical tolerances and assembly logic for the 1:25 scale concept before final prototyping integration.
Phase III: Build Authorization & Assembly
In March, the team finalized design validation and transitioned into active build readiness, securing authorization for the physical assembly of core LTBM subsystems.
- Released finalized CAD models and integrated GD&T drawing packages.
- Received and bench-tested primary motors to validate torque behavior.
- Completed Critical Design Review (CDR) securing build authorization.
- Initiated assembly of core housings to verify sub-assembly fit.
Assembly verification is ongoing as the team transitions into the integrated testing cycle.
Phase IV: Integration & Lab Validation
The April cycle focused on subsystem integration and rigorous lab testing of the LTBM mechanical, electrical, and control assemblies to ensure mission readiness.
- Finalized design across all mechanical and electrical interfaces.
- Integrated control software with motor drivers to resolve kinematic bugs.
- Conducted system-wide electrical load balancing and stress testing.
- Validated regolith-analog handling protocols and subsystem efficiency.
System was optimized for May mission presentation readiness.
Reflection & Strategic Steps
01. LEARNING: LUNAR REGOLITH DISCOVERY
The capstone project taught us valuable engineering skills and how to employ systems engineering by integrating electrical and mechanical systems together. Designing from January to May 2026, we developed a CAD, we iteratively designed using 3D printed parts, assembled the motor controllers, wired 2 Arduinos, and wrote a script to control the cyclic movement of the inch-worm motion, cutterhead, and screw conveyor.
02. NEXT GEN: SCALE-UP ROADMAP
The LTBM prototype successfully validated modular assembly as a vehicle. Moving forward, potential next steps involve integrating the microwave-sintering module for creating the support-rings, including a thermal management system, integrating higher bulk-density rock fragments in testing, and constructing at a 0.5-meter-diameter scale. (The hypothetical concept is a 6-m diameter). We invite research institutes and aerospace industrial partners to collaborate on further subsystem validation.