3D printing of flexible parts out of lunar regolith simulant

On-site manufacturing using lunar regolith holds significant importance for lunar explorations. Concerning the lunar on-site manufacturing, the layer-wise material extrusion approach enables an automated method for fabricating components from lunar regolith blends. In this study, several samples of Thermoplastic Elastomer (TPU) mixed with lunar regolith simulant (10 %, 20 %, and 30 % by weight) were 3D printed using ARBURG Plastic Freeforming (APF) technology within a feasibility study. The mixture ratio and homogeneity of the lunar regolith simulant distribution within the 3D printed samples was assessed using Thermogravimetric Analysis (TGA) and X-Ray Microscopy (XRM). Mechanical properties of the 3D printed TPU samples as well as the mixed TPU with different mixture ratios of lunar regolith simulant were examined using a universal tensile testing machine. Moreover, the internal structures of the 3D printed samples were analysed using XRM. Finally, several functional samples, such as flexible tubes for lunar applications, were 3D printed to demonstrate the capabilities of the APF process. • Novel study; no prior research on extrusion-based lunar regolith composites pellets. • Printed samples using Aurburg Freeforming with TPU and 10 %, 20 %, 30 % regolith. • Mechanical tests show strength decreases with higher regolith content. • Pore sizes increase and pore numbers decrease with more regolith filler. • Printed samples suit indoor-use flexible hardware with strains up to ∼200 %.