The airlock creates a staged transition between the dusty environment of LUNA and the living spaces of FLEXHab - also designed and manufactured by SAGA. Separate coarse and fine airlocks allow crews to test cleaning procedures as they move between surface activities and habitat life.

Connections at either end link the airlock to LUNA and FLEXHab, bringing surface operations and habitat life together. The sequence of doors and spaces gives crews a place to prepare before entering the simulated lunar terrain, and to handle suits and cleaning procedures on their return. The airlock makes this transition part of the training itself.

At the ESA–DLR LUNA facility in Cologne, 700 m² of simulated lunar terrain provides a testing ground for astronauts, tools and surface operations. Controlled lighting recreates the harsh contrasts of the lunar landscape.

The airlock connects this dusty training environment to FLEXHab, bringing surface preparation, suit handling and habitat life into one connected facility.

LUNA uses terrestrial regolith simulant, not material from the Moon. About LUNA · ESA ↗

Suit handling requires room for both the wearer and the assisting team. The overhead support, stowable work surface and accessible equipment keep the preparation area adaptable.

On the Moon, impacts break rock into fine, angular particles over millions of years. Without wind or flowing water to round their edges, these grains remain abrasive. Electrical charging helps dust cling to suits and equipment, making it difficult to leave outside.

Carried into a pressurised space, airborne dust becomes an inhalation concern. Apollo crews reported irritation, while dust also damaged equipment and interfered with seals and mechanisms. Its long-term effects on human health are still being studied.

Returning from a surface excursion brings dust into the airlock on suits and equipment. The design combines staged cleaning, filtered airflow and pressure differences to limit its movement towards the habitat.

Air enters through ceiling-mounted HEPA filters and is extracted through particle filters near floor level. The fine airlock operates at a higher pressure than the coarse airlock, directing airflow towards the dustier zone.

Dust management also shapes the architecture. Smooth surfaces, limited horizontal ledges and flush-folding furniture reduce places where particles can accumulate.

Custom aluminium cabinetry and filter housings provide accessible, cleanable details, while an integrated vacuum system supports routine cleaning.

How much dust becomes airborne when a suit is removed? How do conditions change during cleaning? Measurements help researchers investigate these questions alongside the physical procedures.

The particle instrument measures airborne dust, SAGA’s RAVEN monitors the surrounding environment, and ODIN brings the system information together in a shared interface.

Alongside the airlock, a connecting hallway provides interfaces for additional modules. This creates space for the facility to grow as new research environments and training capabilities are introduced.

Designed and built by SAGA, the airlock is a prefabricated structure made in our Copenhagen workshop before transport to Cologne. Steel framing, aluminium fabrication, ventilation, electrical systems and interior fittings were brought together in-house before installation at the research facility.

The lighting and interior fittings complete the transition from workshop assembly to a working research environment.