Solar Sintering for Lunar Additive Manufacturing

Additive manufacturing (AM) is one of the most promising techniques for on-site manufacturing on extraterrestrial bodies. In this investigation, layerwise solar sintering under ambient and vacuum conditions targeting lunar exploration and a moon base was studied. A solar simulator was used in order to enable AM of interlockable building elements out of JSC-2A lunar regolith simulant. Solar additively manufactured samples were characterized mechanically regarding their compressive and bending properties. Moreover, samples were analyzed morphologically using X-ray tomography and scanning electron microscopy (SEM) followed by density measurements. AM for identical process parameters led to final products with different physical and chemical characteristics when performed under ambient and vacuum conditions. Hence, process parameters were optimized under each individual working atmosphere. The experimental data were further integrated into finite-element (FE) calculations. This led to the refinement of the design of interlocking building elements for lunar applications. These blocks have the potential to form structures for shielding a pressurized inflatable habitat from radiation and micrometeorite impacts or creating nonpressurized shelters for robotic machinery.