Assessing extraterrestrial regolith material simulants for in-situ resource utilisation based 3D printing

Goulas, Athanasios; Binner, Jon; Harris, Russell A.; Friel, Ross J.

doi:10.1016/j.apmt.2016.11.004

Cited by 92 publications

(42 citation statements)

References 28 publications

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“…These tests proved to be successful and a 3D printer has been permanently installed at the ISS for both emergency part creation and for general component production at the ISS for on-going experiments. In addition to studying small FFF 3D printing, significant research has been conducted in the area of using in-situ materials to create large construction projects off-earth [48][49][50][51][52][53].…”

Section: Introductionmentioning

confidence: 99%

Development and Mechanical Properties of Basalt Fiber-Reinforced Acrylonitrile Butadiene Styrene for In-Space Manufacturing Applications

et al. 2019

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A new basalt fiber reinforced acrylonitrile butadiene styrene (ABS) filament has been developed for fused filament fabrication (FFF, 3D printing) to be used in Mars habitat construction. Building habitats on Mars will be expensive, especially if all material must be shipped from earth. However, if some materials can be used from Mars, costs will dramatically decrease. Basalt is easily mined from the surface of Mars. This study details the production process of the material, experimental results from mechanical testing, and preliminary X-ray shielding characteristics. The addition of chopped 3 mm basalt fibers to standard FFF material, ABS, increased strength and stiffness of the composite material. By adding 25% (by weight) basalt fiber to ABS, tensile strength improved nearly 40% by increasing from 36.55 MPa to 50.58 MPa, while Modulus of Elasticity increased about 120% from 2.15 GPa to 4.79 GPa. Flexural strength increased by about 20% from 56.94 MPa to 68.51 MPa, while Flexural Modulus increased by about 70% from 1.81 GPa to 3.05 GPa. While compression results did not see much strength improvements, the addition of fibers also did not decrease compressive strength. This is important when considering that basalt fibers provide radiation shielding and the cost of adding basalt fibers to construction materials on Mars will be negligible compared to the cost of shipping other materials from earth. In preliminary digital radiography testing, it was shown that 77% of X-rays were shielded with 25% basalt fiber added (as compared to neat ABS). In small-scale 3D printing applications, the 25% fiber ratio seems to be the highest ratio that provides reliable FFF printing.

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Section: Introductionmentioning

confidence: 99%

Development and Mechanical Properties of Basalt Fiber-Reinforced Acrylonitrile Butadiene Styrene for In-Space Manufacturing Applications

et al. 2019

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“…There are relatively few researches on laser sintering of lunar regolith/simulant -only three research works (Balla et al 2012, Fateri and Gebhardt 2015, Goulas et al 2017 were found. Despite the thermal transient stresses and residual stresses of direct laser sintering of raw lunar regolith (Balla et al 2012), the initial experiments with the lunar simulants, e.g.…”

Section: Laser and Solar Sinteringmentioning

confidence: 99%

“…Despite the thermal transient stresses and residual stresses of direct laser sintering of raw lunar regolith (Balla et al 2012), the initial experiments with the lunar simulants, e.g. 10 x 25 mm cylinder using JSC-1AC (Balla et al 2012), 30 x 30 mm net-shape object using JSC-1A (Fateri and Gebhardt 2015), and 20 x 20 x 5 mm cube using JSC-MARS-1A (Goulas et al 2017), showed that the samples were successfully melted and formed into the desired parts with high geometrical accuracy. Regardless of the interesting results, however, direct laser sintering alone may not be an ideal fabrication method for a construction-scale object for following reasons:  Balla et al (Balla et al 2012) claimed that their method requires low energy, 2.12 J/mm 2 , with a layer thickness of 254 µm, using 50 W of laser power.…”

Section: Laser and Solar Sinteringmentioning

confidence: 99%

Extra-terrestrial construction processes – Advancements, opportunities and challenges

Lim

Prabhu

Anand

et al. 2017

Advances in Space Research

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“…Apart from the ground environment, the space environment poses severe challenges for metal additive manufacturing technology, including the current heat transfer system, the additive manufacturing process, and heat source equipment [6,7]. Metal wire additive manufacturing technology using a laser beam as a heat source has the advantages of high energy density, high precision, high efficiency, and high flexibility [8,9]. However, in this approach, the device structure is relatively complicated, the power output is high, and the energy utilization rate is relatively low.…”

Section: Introductionmentioning

confidence: 99%

Mechanism of Continuous Melting and Secondary Contact Melting in Resistance Heating Metal Wire Additive Manufacturing

et al. 2020

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Resistance heating metal wire materials additive manufacturing technology is of great significance for space environment maintenance and manufacturing. However, the continuous deposition process has a problem in which the metal melt is disconnected from the base metal. In order to study the difference between the second contact melting of the disconnected metal melt and the continuous melting of the metal wire as well as eliminate the problem of the uneven heat dissipation of the base metal deposition on the melting process of the metal wire, the physical test of melting the metal wire clamped by the equal diameter conductive nozzle was carried out from the aspects of temperature distribution, temperature change, melting time, dynamic resistance change, and the microstructure. The current, wire length, and diameter of the metal wire are used as variables. It was found that the dynamic resistance change of the wire can be matched with the melting state. During the solid-state temperature rise, due to the presence of the contact interface, the continuous melting and secondary contact melting of metal wires differ in dynamic resistance and the melting process. The continuous melting of the metal wire was caused by the overall resistance of the wire to generate heat and melt, and the temperature distribution is “bow-shaped”. In the second contact melting, the heat generated by the contact interface resistance was transferred to both ends of the metal wire to melt, and the temperature distribution is “inverted V”. The microstructure of the metal wire continuous melting and secondary contact melting solidification is similar. The continuous melting length of the metal wire is greater than the melting length of the secondary contact.

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Assessing extraterrestrial regolith material simulants for in-situ resource utilisation based 3D printing

Cited by 92 publications

References 28 publications

Development and Mechanical Properties of Basalt Fiber-Reinforced Acrylonitrile Butadiene Styrene for In-Space Manufacturing Applications

Development and Mechanical Properties of Basalt Fiber-Reinforced Acrylonitrile Butadiene Styrene for In-Space Manufacturing Applications

Extra-terrestrial construction processes – Advancements, opportunities and challenges

Mechanism of Continuous Melting and Secondary Contact Melting in Resistance Heating Metal Wire Additive Manufacturing

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