Ultra-Electrical-Efficient Process to Perform Regolith Additive Manufacturing of Complex Structures

Lunar Resources, an Americanpioneering space industrial companyproposes to NASA the maturation of the Pulsed Electrical Discharge Additive Manufacturing Lunar Surface Construction system (PE3D-LSC). A noveladditive manufacturingsystem optimized forlunar regolith and the lunar environment. The technology does not use binders or reagents to additively manufacture unadulterated regolith and is highly power efficient. During the Phase I effort, the technology was shown to successfully melt lunar regolith in air and vacuum with a quarter of the power required by state-of-the-art laser systems. In addition, a uniqueregolith feed system was also successfully tested to be able to feed the PE3D-LSC with regolith without mechanical mechanisms. During the Phase II effort, the PE3D-LSC will be advanced, with a focus on reducing power input and increasing quality of regolith additive manufacturing parts/structuredin vacuum toenablethe additive manufacture of lunar structures from regolith ingeometries and complexity not before possible on the Moon. Lunar Resources, an American pioneering space industrial company proposes to NASA  the maturation of the Pulsed Electrical Discharge Additive Manufacturing Lunar Surface Construction system (PE3D-LSC). A novel additive manufacturing system optimized for lunar regolith and the lunar environment. The technology does not use binders or reagents to additively manufacture unadulterated regolith and is highly power efficient. During the Phase I effort, the technology was shown to successfully melt lunar regolith in air and vacuum with a quarter of the power required by state-of-the-art laser systems. In addition, a unique regolith feed system was also successfully tested to be able to feed the PE3D-LSC with regolith without mechanical mechanisms.  During the Phase II effort, the PE3D-LSC will be advanced, with a focus on reducing power input and increasing quality of regolith additive manufacturing parts/structured in vacuum to enable the additive manufacture of lunar structures from regolith in geometries and complexity not before possible on the Moon. The technical objective is the mature the PE3D-LSC to TRL 6 by achieving the following objectives: Objective 1: Optimize mechanical and morphological properties of PE3D-LSC regolith glass.  Objective 2: Fully implement PE3D-LSC feed regolith powder transport system.  Objective 3: Characterize the mechanical properties of the fabricated regolith glass. Objective 4: Optimize PE3D-LSC performance in air and in vacuum. Objective 5: Conduct PE3D-LSC system operation at ICON.  The deliverables include reports detailing PE3D-LSC performance and maturation, as well a final demonstration report detailing performance of PE3D-LSC for additvely manufacturing regolith in vacuum compared to state-of-the-art laser systems.

The PE3D-LSC will support NASA and private sector goals of producing in-situ infrastructure on the lunar surface. Key applications include the additive manufacturing of lunar regolith to produce vertical and horizontal structures (landing pads, unpressurized facilities, roads, habitats, pressurized facilities), in-situ photovoltaic substrates, structural elements, concave or parabolic functional structures, radiation shields, and other structures on the Moon.  The PE3D-LSC will support the private sector in constructing and maintaining lunar surface infrastructures such as landing pads, roads, and buildings. It can also be utilized to produce structural elements which can be launched off the Moon and assembled in Cislunar. And the technology can perform additive manufacturing of new high-temperature materials on Earth.

This is early/mid-stage (TRL 5) — the most realistic path in is NASA SBIR/STTR, which funds small businesses and research institutions to develop technology aligned with NASA's needs (equity-free, phased funding). Check whether a current SBIR/STTR solicitation topic overlaps with this project's technology area, or contact the project directly (above) to ask.

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