Researchers map in-space 3D printing possibilities using moon dust
Material sourcing, gravity effects, and monitoring needs for off-Earth fabrication all considered by team, with orbital debris also a potential material
A team of researchers from the University of Nebraska–Lincoln and Purdue University has outlined the key technical barriers to using powder-based additive manufacturing in space environments, with a focus on feedstock characterization under microgravity, vacuum, and extreme temperature conditions. Two primary feedstock sources for in-space AM were identified in lunar regolith and recycled orbital debris.Â
The prohibitive costs of sending materials into space (the SpaceX Falcon 9’s 2024 launch carry cost was $12,682 per kilogram), combined with the long-terms goals of sending humans to the moon as part of projects such as NASA’s Artemis mission, mean that ways of establishing cost-effective and realistic options are continually being explored.
Tests have also recently been done using simulated lunar soil in laser 3D printing processes for the construction of durable, heat-resistant structures.
Regolith and debris as feedstocks
Lunar regolith presented a natural fit for powder-based processes, with 90% of particles falling below 1,000 micrometers. However, its jagged, irregular morphology — shaped by meteorite impacts in the absence of any atmosphere — complicated flowability and packing density compared to the spherical powders used in Earth-based AM systems.Â
Martian regolith posed additional challenges: it contains toxic perchlorate compounds and hydrated minerals that could affect both manufacturing safety and structural integrity of printed parts.
Orbital debris offered a metal feedstock source. The review described a multi-stage recycling pathway involving robotic collection, spectroscopic sorting, thermal preprocessing, plasma or electron beam atomization, and rigorous characterization prior to use in AM systems.
Environmental effects on powder behavior
Microgravity, vacuum, and temperature extremes can alter powder behavior in ways that standard Earth-based characterization methods do not account for. In reduced gravity, Van der Waals interparticle forces became dominant across larger particle sizes, increasing the risk of clogging and agglomeration.
Lunar surface temperatures ranging from −250 to 250ºC further affect flowability by altering particle shape, yield strength, and triboelectric charging.
Of the powder production methods evaluated by the team, electrolysis was identified as the most viable for space applications due to its reliance on electricity — which could be supplied by solar power — and its independence from gravity.
The researchers also identified dynamic image analysis and electrical sensing zone measurement as among the most promising characterization techniques for microgravity conditions.
The work was published as a peer-reviewed article in npj Advanced Manufacturing.
