1.
Solar 3D printing of lunar regolith
Alexandre Meurisse
April 12th 2018

2.
The project aims at developing a 3D-printing process for fusing/melting/sintering model lunar soil
material with the use of concentrated solar energy. The intended first result is a brick-sized model
building block of a lunar base outer shell made from model material. The project shall study various
parameters of the production process as well as of the model lunar soil in order to better understand
and optimise the overall process also in view of application on the Moon.
ESA-GSTP: 3D printing of a model building block for a lunar base outer shell (2015-2017)
Background & Context
The establishment of a permanent base on the lunar surface will require the construction of roads and
habitats shielding from meteoroids and space radiation. In-Situ Resource Utilisation (ISRU) would be a
solution to reduce up-mass, cost, and risk of such lunar mission.
Solar sintering of lunar regolith

3.
ESA-GSTP: 3D printing of a model building block for a lunar base outer shell
Solar 3D printing of lunar regolith
DLR-Cologne Solar Oven

4.
Solar 3D printing of lunar regolith

5.
Powder dispenser
Solar 3D printing of lunar regolith

6.
12
3 4
Testbed
2D
190 mm
60 mm Thickness ≈1 mm
Solar 3D printing of lunar regolith

7.
SEM images of solar sintered JSC-1A

8.
Xenon High-Flux Solar Simulator
Steady light conditions
Higher sintering quality
Closer to the lunar environment
Power density
1.2 MW/m²
ESA-GSTP: 3D printing of a model building block for a lunar base outer shell

9.
ESA-GSTP: 3D printing of a model building block for a lunar base outer shell
Solar 3D printing of lunar regolith

10.
Solar 3D printing of lunar regolith
ESA-GSTP: 3D printing of a model building block for a lunar base outer shell

11.
Solar 3D printing of lunar regolith

12.
150
mm
180
mm
200 mm
20
mm
50
mm
http://www.esa.int/spaceinvideos/Videos/2017/03/3D-
printing_moondust_bricks_with_focused_solar_heat
Solar 3D printed parts
ESA-GSTP: 3D printing of a model building block for a lunar base outer shell

13.
COMSOL solar 3D printing simulations
Model Loose

14.
Solar 3D printing of lunar regolith
ESA-GSTP: 3D printing of a model building block for a lunar base outer shell
ESA-RAL AML: Particle size analyser

15.
Differential scanning calorimetry

16.
Temperature XRD

17.
Traditional sintering
Commun sintering parameters
Pre-compaction 255MPa
Sintering time 3h
Heating rate 400°C/h
JSC-1A sintered in air JSC-1A sintered in vacuum
25mm
20mm
Simulant JSC-1A JSC-2A DNA FJS-1 NULHT
Environement Air Vac. Air Vac. Air Vac. Air Vac. Air Vac.
T(°C) 1125 1100 1130 1090 1100 1070 1125 1090 1200 1200

18.
Scanning electron microscopy
JSC-1A sintered under vacuum JSC-1A sintered in air

19.
JSC-1A with ilmenite addition
Ilmenite: FeTiO3

20.
Radiation shielding
HZE, High energy ions
neutrons
- “The purpose of shielding is to reduce exposure […] as low as reasonably achievable.”
Ref: Turner, Ronald. "Solar particle events from a risk management perspective." IEEE transactions on plasma science 28.6 (2000): 2103-2113.
Ref: C. Zeitlin, S. B. Guetersloh, L. H. Heilbronn, and J. Miller. Measurements of materials shielding properties with 1GeV/nuc 56Fe. Nuclear
Instruments and Methods in Physics Research Section B: Beam Interactions with Materials and Atoms, 252(2):308–318, 2006.

21.
ISIS Neutron and Muon Source
RAL Space
Harwell Science & Innovation Campus

22.
ISIS spallation source
CHIP-IR
Atmospheric neutrons

23.
Radiation shielding
We count the neutrons with a silicon detector before and after the samples
Samples
Powder samples were
placed in an aluminium
tube and then wrapped
in aluminium foil.
Neutron
flux
Si Detector
Si Detector
Sample
holder

24.
Radiation shielding
Experimental set-up
We count the neutrons with a silicon
detector before and after the samples
A second device « ESA-SRAM »
cross-checks the neutron counts
Counter 1, 2 and 3 is the same
counter with different
thresholds

25.
Radiation shielding
Interaction Depth: X= ρ . 𝑑𝑟
Results
We measured JSC-2A at powder state,
traditionally sintered in vacuum and solar
sintered. Also aluminium for comparison
purposes.
The results are compared with Monte-Carlo
simulations
The depth is in g.cm-2 as the material density
is integrated by its thickness in order to plot
all the results together.
In principle, all JSC-2A samples should be
aligned.
ρ: 𝑚𝑎𝑡𝑒𝑟𝑖𝑎𝑙′ 𝑠 𝑑𝑒𝑛𝑠𝑖𝑡𝑦

26.
TRL 5
TRL 4
TRL 3
TRL 2
TRL 1
TRL 6
p.
26Funded by EU-Horizon 2020
Planning the next step
• First solar 3D
printing of lunar
regolith
• Mobile 3D printing head
• Solar sintering in
vacuum
• Traditional sintering
of lunar regolith
* Building bigger
elements in a relevant
environment (vacuum,
reduced gravity)
* Mission scenario &
Readiness
* Improved mechanical
properties
* Material scientific
understanding of material

27.
p.
27Funded by EU-Horizon 2020
Solar sintering
Mobile 3D printer
• demonstrates printing operations
in an operational setting closer in
scale to one that would be used
on the moon surface
• comprised of a lightweight lens
oriented in a 3-dimensional space
• lens moves, as opposed to the
sintering bed
• allows the construction of larger
building blocks
reuses:
feeder (FEMA)
software components (NCGU)

28.
p.
28Funded by EU-Horizon 2020
Solar sintering
Mobile 3D printer
Campaign II - Example of printed layer with
enhanced resolution of mobile printing head

29.
p.
29Funded by EU-Horizon 2020
Solar sintering
Vacuum 3D printer
• similar to the ambient 3D printing
system
• compatible with a vacuum
chamber
• modifications include:
• reduction in capacity of the
hopper (FEMA)
• disposition and geometry of
the auger conveyors (FEMA)

30.
p.
30Funded by EU-Horizon 2020
Building Elements
Interlocking building elements
• Extensive geometric studies
were undergone
• geometries are adapted in an
iterative process after each
sintering campaign in
coordination with the material
tests
Tetrahedron
• self-centers during construction
- eliminating the need for
external scaffolding
• has sharp edges and allows the
construction of a completely
sealed habitat envelope
Optimization of the tetrahedron interlocking
building element; final geometry pictured in version
13.

31.
p.
31Funded by EU-Horizon 2020
Building Elements
Lunar habitat envelope
constructed through tetrahedron
elements
The interior can be outfitted with
inflatable pressure-bearing
volumes to create inhabitable
zones

32.
Thank you for your attention