Abstract:
This study explores additive manufacturing (AM) techniques using extraterrestrial materials. We compare microwave sintering vs. solar-thermal methods for regolith-based structures and evaluate mechanical properties.
Technical Depth:
Regolith Sintering: Microwave processing (2.45 GHz, 800–1,200°C) achieves 75–85% density with 20–30 MPa compressive strength. Solar furnaces (1,500°C) improve strength to 45 MPa but require 8–12 hours per layer.
Material Blending: Adding 5–10% ilmenite (FeTiO₃) increases flexural strength by 40% due to glass-phase bonding. Basalt fibers (from Martian soil) enhance tensile strength by 35%.
Print Path Optimization: Genetic algorithms reduce void defects by 28% in complex geometries (e.g., habitat airlocks).
Innovation:
A hybrid AM system combining microwave pre-heating and laser-assisted binder jetting enables 1 m3/hour printing rates, sufficient for constructing a 50 m3 habitat in 50 days.
