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Advancements in 3D Printing with Lunar Regolith

Recent developments in 3D printing technologies using lunar regolith have shown promise, with various initiatives exploring the potential of creating objects from this material. Unlike previous projects that rely on additives like polymers or saltwater as binding agents, a new study led by Julien Garnier and colleagues at the University of Toulouse seeks to produce compression-hardened 3D-printed items using only regolith itself. This research was published in Acta Astronautica.

The high cost of transporting materials to space makes it critical for any 3D printing technology to minimize dependence on terrestrial supplies. For instance, AI Spacefactory’s approach includes using Earth-based polymers that must be shipped to the Moon, increasing logistical challenges.

In their study, Dr. Garnier and his team employed selective laser melting (SLM) on a specific lunar regolith analog known as Basalt of Pic d’Ysson (BPY). Collected from an extinct volcano in France, BPY has gained traction as a lunar regolith simulant due to its similar chemical and mineral composition to the basaltic rocks found on the Moon.

Prior research has highlighted BPY’s potential in lunar 3D printing. The European Space Agency (ESA) has explored a “solar sintering” method that utilizes sunlight to fuse BPY powder, while the MOONRISE project has investigated BPY in zero-gravity printing contexts.

Despite its promise, past studies have raised concerns about the compressive strength of BPY when 3D printed. Structures on the Moon, although subjected to lower gravity, still experience considerable stresses. Materials with inadequate compressive strength cannot efficiently serve as building materials, regardless of the lunar environment.

Compressive strength measurements for BPY printed using different techniques have shown variability. For example, processes like Powder Bed Fusion, commonly employed for metals, yielded a compressive strength of approximately 4.2 MPa, which is slightly higher than that of standard masonry bricks. However, this strength was achieved with a porosity of nearly 50%, indicating significant structural weaknesses.

To enhance BPY’s mechanical properties, Dr. Garnier’s research focused on the characteristics influencing compressive strength. The experiments contrasted “crystalline” and “amorphous” powder forms. Crystalline powders exhibit an ordered structure, leading to variable properties depending on crystal alignment, while amorphous powders display uniform physical characteristics regardless of direction.

Notably, results indicated that compressive strength doubled when utilizing 100% crystalline powders compared to those that were entirely amorphous. This discovery underscores the critical nature of regolith structure in developing effective construction materials for future lunar bases.

Optimizing the balance between crystalline and amorphous structures, along with adjusting particle sizes and SLM parameters, remains a key focus for ongoing research. As efforts to return humans to the Moon gather momentum, the utilization of lunar resources for construction may soon become feasible, potentially employing innovative techniques such as laser melting.

More information:
Julien Garnier et al, Selective laser melting of partially amorphous regolith analog for ISRU lunar applications, Acta Astronautica (2024). DOI: 10.1016/j.actaastro.2024.10.024

Citation:
Quality of 3D printing with lunar regolith varies based on feedstock (2025, April 28) retrieved 28 April 2025 from https://phys.org/news/2025-04-quality-3d-lunar-regolith-varies.html

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phys.org