Magnetic beneficiation – A novel approach to facilitate additive manufacturing of lunar regolith ceramics by vat photopolymerization

Using lunar regolith in on-site additive manufacturing (AM) is critical for future crewed lunar missions, enabling the on-demand fabrication of tools, spare parts, and infrastructure. Stereolithography-based AM shows promise for fabricating precise and durable regolith-derived ceramics, but its heterogeneous mineral composition and granulometry pose challenges during the 3D-printing and sintering stages. This study explores magnetic beneficiation as a strategy to enhance the processability of LHS-1 lunar regolith simulant for vat photopolymerization-based AM. We have explored the impact of preliminary magnetic beneficiation of LHS-1 lunar regolith simulant on its printability and sintering behaviour by assessing the mechanical properties and microstructure of 3D-printed ceramic parts. It was found that by selectively removing the magnetic fraction, it is possible to achieve a sixfold reduction in exposure time per layer (from 60 to 10 seconds), enabling faster and more efficient printing. Sintered ceramic specimens exhibited 10% higher density and 30% greater flexural strength than the ones derived from the untreated highland regolith, demonstrating improved mechanical performance and microstructural uniformity. Characterization via DTA-TG, XRD, SEM-EDX, and mechanical testing confirmed the strong influence of beneficiation, particularly basalt content, on the final parts’ properties. This study demonstrates the high potential of preliminary beneficiation for enhancing the performance of vat-polymerization AM with lunar regolith, paving the way for advanced fabrication capabilities on the Moon. • Magnetic beneficiation of lunar regolith significantly improves its suitability for vat-polymerization-based additive manufacturing by enhancing both the printability and the properties of sintered ceramic samples • Exposure time per printed layer was reduced sixfold (from 60 to 10 seconds) after magnetic fraction removal, enabling faster and more efficient DLP printing • Sintered ceramic parts produced from magnetically beneficiated regolith showed 10% higher density and 30% higher flexural strength compared to parts made from untreated material. • Comprehensive material characterization (DTA-TG, XRD, SEM-EDX, mechanical testing) revealed improved microstructural homogeneity and more consistent mechanical properties due to the reduced basalt content. • Obtained results show the viability of preliminary magnetic beneficiation to improve the printability of lunar regolith and support sustainable on-demand manufacturing of ceramics for future lunar missions.