Optimizing Lunar Regolith for Vat Polymerization and Sintering: Pre-processing & Mineral Composition Impact

Lunar regolith is the most abundant resource on the lunar surface, which can be used for in-situ fabrication and repair technologies. Vat photopolymerization-based additive manufacturing is among the most promising techniques, capable of producing precise ceramic parts of complex shapes from the lunar regolith feedstock for the needs of future crewed exploration missions to the Moon. One of the under-studied aspects of additive manufacturing with lunar regolith is the pre-and post-treatment procedures, which would ensure optimal energy and material consumption and the best printing performance. The goal of the present article was to define the influence of the mineral composition of lunar regolith simulants and the parameters of their pre-processing on the properties of sintered regolith ceramics. It was found that the highland regolith could be sintered to higher relative density compared to the mare regolith. The optimal sintering temperature was determined to be 1150 °C for both types of lunar regolith. An optimal mineral and fractional composition for the regolith feedstock was determined based on the trade-off analysis between lunar regolith sinterability and its printability via vat photopolymerization-based additive manufacturing. Vat-polymerization was performed to produce complex-shaped ceramic parts, yielding 95 % of relative density and a mean ultimate flexural strength of 106 ± 5 MPa, confirming the proposed trade-off point.