Overview
- Researchers used laser powder bed fusion, a layer‑by‑layer laser sintering method, to turn Lunar Highlands Regolith Simulant (LHS‑1) into small interlocking H‑ and cross‑shaped bricks that fit together like LEGO pieces.
- The work is a peer‑reviewed proof of concept published in npj Advanced Manufacturing that demonstrates binder‑free manufacture of reconfigurable components from simulated moon dust.
- Printed pieces supported their own weight but were notably more porous and mechanically weaker than samples made with added binders, limiting their current use for load‑bearing structures.
- The project was led by undergraduate Cole McCallum with Wan Shou as senior author, and the student‑led nature of the work highlights how undergraduates can contribute to early-stage space engineering research.
- Before any lunar deployment the team says the process must be tested under vacuum and reduced gravity, scaled up, and optimized to improve density and strength, which will determine whether the method can cut the mass of materials sent from Earth.