Originally Posted by
Skroe
Well its a little bit more complicated than that. The Current SLS Manifest has EM-1 launching about a year from now (unmanned, though thats mostly to save money on human rating the Delta Interim Upper-stage), followed by the Europa Clipper probably around 2021/2022. The first manned mission, EM-2, will launch in 2022, and Astronauts will do annual trips around the moon for 3-5 weeks from 2022-2026. The Gateway Platorm will take 4 launches and 4 years to build, as the launch capacity of the SLS Block 1B, at 105 tons, can easily carry the Orion Capsule, it's service module and a payload. That's actually kind of the thing with the SLS... it's amazing for payloads but overkill for crewed capsule missions.
There will likely be a several more Deep Space science and National Security missions using the SLS around this, but that the present the plan is to launch SLS Block IB+Orion once a year through the 2020s.
The problem is fundamentally one of economics and industrial capacity. The SLS core stage is a good more complicated to manufacture than the old Shuttle External tank on which it is based. Program engineers had to invent this enormous weilding device the size of a building in order to weild the tank in any kind of cost-effective manner. The SLS is projected to cost $550 million a mission. Throw in program cost and support, it'll probably be over $1 billion for the 105t to LEO "workhorse" model. 105t sounds like a lot, but here's the horrifying thing: it's $550m per flight to launch 105t, when a C-5 Galaxy can fly nearly the same amount of payload (its full load) at a cost of $78,000 per flight hour.
Space is hard, space is expensive, and everything sucks.
Add that to the fact that the NASA Mars reference design has the Mars Transit Vehicle taking between 9 and 11 flights, which would have to be launched within a construction period of around 2-3 years sometime after 2030, and you see the problem. And that doesn't include all the SLS flights to Mars around the same time to send habitation modules, support equipment, Mars landers and everything else.
If the SLS can establish economies of scale to drive down cost of building and launching at a high tempo, is it possible? Sure. But its never been done. 11 SLS flights in three years is mindbogglingly aggressive. And it's not even a matter of money (because people LOVE to throw Money at NASA to fulfill their dreams). Can Orbital ATK build 22 SRBs for those missions? Can the facilities safely process all 11 SLSs? Big question.
You menttion off-planet manufacturing. While for some things that is certainly a solution (fuel, concrete-like building materials on Mars), there is no known way we can manufacture essential things like rubber, or plastics (petroleum derivities). Ideally, using the low-gravity moon as a staging ground for exploration into the Solar system would be ideal, but any kind of offplanet manufacturing for more than fuels has a serious question of how do they turn the raw materials at one or several locations, into something useful and safe to use. That kind of infrastructure could take a century or more to build. Hell, the US space program gets raw materials from all over the world from countless suppliers. A lunar factory of any type would not have nearly that kind of supply chain.
Which is to say, while orbital facities have their usage (particularly refueling for the launch of larger payloads), missions anywhere into the solar system will remain tethered to Earth for centuries to come because the process or the infrastructure to create useful raw materials beyond fuels is still far beyond us.
This is why SpaceX's model is probably the best for now. It just wins on economics. But even SpaceX's largest, most capable vehicles on the drawing board pale in comparison to the economics of a C-5 Galaxy. However, the second they can get a 105t launch vehicle flying for about $2 a pound, space infrastructure will take off very quickly. The Falcon Heavy's cost per pound for reference, is about $850. That sounds a lot, but here's the good news: the Space Shuttle's cost was $10,000 per pound, and the Delta IV Heavy's cost is $9000 per pound, and the Falcon Heavy can launch over twice the payload of either of them. So cost savings on the scale we're talking about have actually happened in the last 30 years.