Researchers transform simulated lunar regolith into robust, heat-resistant structures using advanced laser 3D printing, opening doors to sustainable moon bases for NASA’s Artemis missions.
Laser-Based Fabrication Process
A team melts synthetic moon soil, known as LHS-1 regolith simulant from lunar highlands, layer by layer with a specialized laser. This fuses the fine, dusty material to a base surface, creating small objects capable of withstanding extreme temperatures. Such technology promises nontoxic habitats and tools essential for long-term human presence on the moon by decade’s end.
Testing under varied conditions reveals that material quality hinges on the printing surface. LHS-1 adheres strongly to alumina-silicate ceramic, forming crystals that boost thermal stability and mechanical strength. Printing on stainless steel or glass proves more difficult.
Environmental Factors Influence Performance
“By combining different feedstocks, like metal and ceramics, in the printing process, we found that the final material is really sensitive to the environment,” states Sizhe Xu, lead author and graduate research associate in industrial systems engineering at The Ohio State University. “Different environments lead to different properties, which directly affect the mechanical strength and the thermal shock resistance of certain components.”
Other variables, including atmospheric oxygen levels, laser intensity, and printing speed, also affect structural integrity. “There are conditions that happen in space that are really hard to emulate in a simulant,” notes Sarah Wolff, senior author and assistant professor in mechanical and aerospace engineering at The Ohio State University. “It may work in the lab, but in a resource-scarce environment, you have to try everything to maximize the flexibility of a machine for different scenarios.”
Advancing In-Situ Resource Utilization
Developing reliable systems for space manufacturing tackles key hurdles in human exploration. In-Situ Resource Utilization (ISRU) harnesses local materials to endure vacuum, dust, and thermal extremes, cutting the need to ship heavy loads from Earth. Additive manufacturing enables on-site production of structures, tools, and habitats, saving time and boosting mission independence for deep-space voyages.
Future systems may shift from electric power to solar or hybrid sources for scalability. The research highlights the need for more data to address limitations.
Earthly Benefits and Broader Applications
“There are so many applications that we’re working toward that with new information, the possibilities are endless,” Xu adds. Beyond space, these insights could solve material shortages on Earth by promoting resource-efficient manufacturing.
“If we can successfully manufacture things in space using very few resources, that means we can also achieve better sustainability on Earth,” Wolff explains. “To that end, improving the machine’s flexibility for different scenarios is a goal we’re working really hard toward.”
Co-authors from The Ohio State University include Marwan Haddad, Aslan Bafahm Alamdari, Annabel Shim, and Alan Luo. The study appears in Acta Astronautica (DOI: 10.1016/j.actaastro.2025.11.070).
