Session: 03-09-01: Materials for Extreme Environments

Paper Number: 183350

183350 - Development of 3d Printable Polymer-Lunar Regolith Composite Material 

Advanced composites that utilize locally sourced materials capable of undergoing mechanical loads in harsh environments are critical to the future of exploration and habitation of the lunar surface. The use of lunar regolith in these material systems through in-situ resource utilization (ISRU), makes it possible to achieve application specific material systems while reducing transportation masses for general-use materials. Further, these materials can be additively manufactured to fabricate parts with desirable material properties and recycled to establish a circular economy on the lunar surface. This study advances a methodology of extruding and additively manufacturing polymer-lunar regolith composites through fused filament fabrication (FFF) 3D printing. We systematically investigate the thermal and mechanical properties of the composite materials and examine the composite recycling process to determine methods for maximizing material recovery. Previous studies have explored various methods of 3D printing with lunar regolith. However, limited research has examined fused filament fabrication (FFF) of polymer–lunar regolith composites, with most focusing primarily on print parameter effects. Moreover, few studies have investigated the recycling of these composites, particularly evaluating processes designed to achieve high material recovery rates. This study will expand on the current knowledge of FFF 3D printing and recycling of polymer-lunar regolith composites by investigating the response of composite materials and their recycled components to thermal and mechanical loading.  This study will evaluate the performance of the composites as a function of lunar regolith loading level and particle size, as well as assess the performance of recycled components based on the recycling process used. To develop the material system, a single screw extrusion system is used to blend polylactic acid (PLA) polymer pellets with lunar regolith simulant and produce a 3D printable filament. The 3D printing parameters were selected based on the thermal response of the material determined by thermogravimetric analysis (TGA) and differential scanning calorimetry (DSC). After 3D printing, the materials were analyzed using dynamic mechanical thermal analysis (DMTA) and mechanical (tensile) testing. After testing, the composite material was recycled by mechanically preparing the material through a granulating and sieving process, then using a solvent to separate the constituent materials. This study will provide an understanding of how to manufacture composite materials through ISRU processes on the lunar surface, recycle the material using a process feasible for implementation on the lunar surface to recover reusable composite material, and provide further knowledge on potential applications for the material system based on the material properties evaluated.

Presenting Author: Addie Kriger Auburn University

Presenting Author Biography: Addie Kriger is an undergraduate researcher who has been an active member of the lab for some time and currently holds an undergraduate research fellowship. Her project focuses on the development and recycling of lunar regolith composite materials, with an emphasis on separating and recovering the polymer and regolith components for reuse in sustainable space manufacturing applications.