Characterization of Lunar Regolith-Metal Powder Mixtures for Manufacturing in Space

With renewed interest in Lunar exploration, scientists are investigating the colonization of the moon. Building lunar habitats requires high strength materials and fast processing. The process of additive manufacturing (AM), colloquially known as 3D printing, is ideal for this approach. Utilizing in-situ materials represents an abundant resource for building with AM in space. One such material is lunar regolith, the loose powder material that covers the moon’s surface.

Utilizing a lunar regolith simulant and SS316 powder, we investigated the optimal percentages of each material and the effects of different metal powder size distributions (PSD) on the powder characteristics. For use in AM, the flowability and packing density are vital to the success of the final parts. The method used for this project mimics powder-based AM techniques, such as Laser Powder Bed Fusion (LPBF). In LPBF, the material particles must be able to flow without packing as this could jam the machine or create an inconsistent or porous part.