3D Printing Metal Parts on the Moon: Advancements in Lunar Manufacturing

Jun 24, 2023

Additive manufacturing, also known as 3D printing, is steadily gaining traction in various industries as technology continues to improve. One area where it holds great potential is in space exploration, particularly for in-situ resource utilization (ISRU) efforts. The European Space Agency (ESA) is supporting research in this field, funding the work of Austrian company Incus to develop a 3D printing solution capable of printing metal parts on the Moon.

The process of manufacturing metal from lunar ore is energy and time-consuming, which is not feasible in early lunar exploration scenarios. Recycling existing metal is a more straightforward approach. Incus employs a technique called Lithography-based Metal Manufacturing (LMM), which involves combining metallic powder with a binding agent and curing the blend using ultraviolet light. The resulting mixture is then sintered to create completed metal parts, minimizing waste compared to traditional subtractive manufacturing processes.

However, lunar dust poses a challenge to this process. Lunar dust is known for its stickiness and can interfere with the curing and binding of printed metal parts. It becomes particularly problematic for recycling projects that utilize metal from rovers and solar panels, as they are exposed to lunar dust for extended periods. Cleaning such components thoroughly before recycling is impractical. Incus conducted research sponsored by ESA, using both new and recycled titanium mixed with varying percentages of lunar dust to assess the impact on the printing process.

Surprisingly, the results were positive. While high concentrations of lunar dust powder affected the viscosity of the printed parts, adjusting the binder-to-powder ratio ensured the parts met the required porosity standards. However, further work is needed to explore printing other types of materials, such as iron/steel, and to determine if higher concentrations of lunar dust require additional filtration processes for recycling. ESA intends to continue supporting Incus and its partners to further advance lunar manufacturing capabilities.

These advancements in 3D printing metal parts on the Moon have significant implications for future space missions and the establishment of lunar bases. By utilizing local resources and reducing reliance on Earth supplies, space agencies can enhance sustainability and self-sufficiency in space exploration.