Additive construction: State-of-the-art, challenges and opportunities

Directed energy deposition (DED) additive manufacturing: Physical characteristics, defects, challenges and applications

Solar 3D printing of lunar regolith

Selective Laser Melting (SLM) is a candidate for on-site manufacturing as its characteristics of energy source and powder-based fabrication process are suitable for use with in situ material. The feasibility of using lunar regolith simulant to create objects with SLM process is investigated in this study. The process parameters are optimized and multiple objects are fabricated. A qualitative chemical analysis is carried out with scanning electron microscopy using energy-dispersive X-ray emission. Lastly, properties such as particle size distribution, particle shape, and crystal structure of the lunar simulant powder as well as the crystallinity and hardness of the fabricated objects are investigated.

Process Parameters Development of Selective Laser Melting of Lunar Regolith for On‐Site Manufacturing Applications

Here, we present a comprehensive approach for creating robust, elastic, designer Lunar and Martian regolith simulant (LRS and MRS, respectively) architectures using ambient condition, extrusion-based 3D-printing of regolith simulant inks. The LRS and MRS powders are characterized by distinct, highly inhomogeneous morphologies and sizes, where LRS powder particles are highly irregular and jagged and MRS powder particles are rough, but primarily rounded. The inks are synthesized via simple mixing of evaporant, surfactant, and plasticizer solvents, polylactic-co-glycolic acid (30% by solids volume), and regolith simulant powders (70% by solids volume). Both LRS and MRS inks exhibit similar rheological and 3D-printing characteristics, and can be 3D-printed at linear deposition rates of 1–150 mm/s using 300 μm to 1.4 cm-diameter nozzles. The resulting LRS and MRS 3D-printed materials exhibit similar, but distinct internal and external microstructures and material porosity (~20–40%). These microstructures contribute to the rubber-like quasi-static and cyclic mechanical properties of both materials, with young’s moduli ranging from 1.8 to 13.2 MPa and extension to failure exceeding 250% over a range of strain rates (10–1−102 min−1). Finally, we discuss the potential for LRS and MRS ink components to be reclaimed and recycled, as well as be synthesized in resource-limited, extraterrestrial environments.

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Robust and Elastic Lunar and Martian Structures from 3D-Printed Regolith Inks.

Purpose – The purpose of this paper is to evaluate the feasibility of direct fabrication of lunar/Martian regolith simulant parts, in a freeform environment, using Laser Engineering Net Shaping (LENS™) – an additive manufacturing technology.Design/methodology/approach – Bulk lunar regolith simulant structures were fabricated using a LENS™‐750. Dense parts without any macroscopic defects were produced at a laser power of 50W, a scan speed of 20 mm/s, and a powder feed rate of 12.36 g/min. The laser processed parts were characterized using X‐ray diffraction, differential scanning calorimetry, scanning electron microscope and X‐ray photoelectron spectroscopy to evaluate the influence of laser processing on the microstructure, constituent phases and chemistry of lunar regolith simulant.Findings – A combination of laser parameters resulting in a 2.12 J/mm2 laser energy appeared to be ideal for generating a melt pool necessary for lunar regolith powder deposition without excessive liquid pool spreading and crac...

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Gregory W. O. OConnor

Papers

First Demonstration on Direct Laser Fabrication of Lunar Regolith Parts