Additive Manufacturing of Lunar Regolith via Resin-Based Binder and Material Extrusion Method for High-Performance In-Situ Manufacturing on the Moon (2025-07)¶

The utilization of lunar regolith for construction on the lunar surface presents a critical challenge in in-situ resource utilization. This study proposes a lunar regolith manufacturing method that uses a high-performance resin binder characterized by a high regolith content and strong forming capabilities. A combined resin material with both thermosetting and photosetting properties was developed and mixed with lunar regolith to create a slurry. This slurry can be directly molded or additively extruded into green bodies with specific structures. These green bodies can self-cure under the high temperatures and ultraviolet radiation experienced during the lunar day, reducing energy consumption and fulfilling the requirements of lunar construction. The material-forming processes and effects of various additive types and concentrations, regolith mass ratios, and processing parameters on the properties of the slurry and the formed specimens were thoroughly investigated. The mechanical performance and microstructure of the fabricated samples were analyzed. The lunar regolith mass ratio reached 90 wt% (approximately 79 vol%), with the highest compressive strengths exceeding 60 MPa for cast specimens and 30 MPa for printed samples. This technology shows significant potential for enabling in-situ lunar regolith-based construction in future lunar missions.