Key Takeaways & Executive Findings
- •• LPBF-printed highland lunar regolith simulants exhibit superior mechanical strength (5.79 MPa) and ductility (peak strain 0.13) compared to mare simulants, making them promising for lunar construction. • Wire-cutting introduces defects that reduce strength by ~20% and ductility significantly, highlighting the need for careful post-processing in ISRU manufacturing. • 3D-DIC reveals distinct strain localization patterns (band-type, diffuse, network-type) depending on simulant type and cutting, providing insights into failure mechanisms. • An energy-based damage model, validated experimentally, captures the three-stage energy evolution (elastic storage, progressive dissipation, unstable collapse), offering a predictive tool for lunar habitat structures.
Abstract
Targeting Chang’E-8 mission’ in-situ resource utilization (ISRU) for sustainable lunar habitats, laser powder bed fusion (LPBF) provides a viable pathway for in-situ additive manufacturing of lunar regolith. To elucidate mission relevant mechanical behavior and failure mechanisms of LPBF fabricated lunar regolith simulants, mare type and highland type simulant specimens were produced. Microstructural characterization, mechanical test coupled with three-dimensional digital image correlation (3D-DIC), and an energy-dissipation framework were employed for comprehensive analysis. The pristine highland specimens achieved 5.79 MPa and a peak strain of 0.13 (50 mm × 50 mm × 30 mm), significantly outperforming their mare counterparts. Wire-cutting to 20 mm × 20 mm × 20 mm lowered strength by ∼ 20% and peak strain to 0.04, indicating cutting-induced defects reduce ductility. All specimens displayed multi-peaked stress–strain curves. 3D-DIC revealed band-type strain localization in pristine highland samples, diffuse strain patterns in cut highland samples, and highly tortuous, network-type bands in mare samples; the anisotropy index was also quantified. Fragmented particles exhibited fractal dimensions ranging from 1.6 to 2.0 (size 1.25–9 mm). Energy evolution progressed through three distinct stages: elastic energy storage, progressive energy dissipation delaying crack propagation, and final unstable collapse. An energy-based damage model was established and validated. The data and methods developed support Chang’E-8 missions’ ISRU demonstrations and establish a transferable framework toward sustainable lunar habitats.
1. Introduction
The large-scale utilization of lunar resources—such as noble metals, rare-earth elements, and 3 He—has emerged as a focal point of contemporary research and is expected to drive new sectors within the space economy [1]. Establishing a lunar base is a prerequisite for such activities, and in-situ resource utilization (ISRU) of lunar regolith for construction materials and structures is considered the most feasible technological pathway [2]. Within this context, the Chang’E 8 mission is planned to conduct on surface ISRU demonstrations, including regolith printing trials, to address major lunar science and development needs and to mature enabling capabilities that will support future sustainable lunar habitats.
Additive manufacturing has been proposed as an effective route for in situ lunar fabrication, with processes including hot-press vacuum sintering, microwave sintering, and selective laser melting already demonstrating feasibility [3,4]. Among these, laser powder bed fusion (LPBF) is regarded as one of the most engineering-ready ISRU technologies due to its high precision, strong process controllability, binder-free operation, and adaptability to the extraterrestrial environment [5].
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Sheng Li, Xinyi Li, Yuyue Gao, Bo Zhou, Yan Zhou, Jian Song, Cheng Zhou, Wei Yao, Lieyun Ding (2025). Towards sustainable lunar habitats with ISRU in Chang’E mission: Mechanical–energy evolution and damage mechanisms of LPBF-printed lunar regolith simulate. International Journal of Mining Science and Technology. https://doi.org/10.1016/j.ijmst.2025.11.003
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Frequently Asked Questions
What is the significance of this research for lunar habitat construction?
This research demonstrates that LPBF-printed lunar regolith simulants, especially highland type, possess sufficient mechanical strength and ductility for building structures on the Moon, supporting ISRU-based sustainable habitats as planned for the Chang’E-8 mission.
How does wire-cutting affect the mechanical properties of LPBF-printed lunar regolith?
Wire-cutting to smaller dimensions reduces compressive strength by about 20% and peak strain from 0.13 to 0.04, indicating that cutting-induced defects significantly lower ductility and overall mechanical performance.
What methods were used to analyze the mechanical behavior and failure mechanisms?
The study employed microstructural characterization, mechanical testing coupled with three-dimensional digital image correlation (3D-DIC) to observe strain localization, and an energy-dissipation framework to quantify energy evolution during deformation.
What are the key findings regarding energy evolution and damage?
Energy evolution occurs in three stages: elastic energy storage, progressive energy dissipation that delays crack propagation, and final unstable collapse. An energy-based damage model was established and validated, providing a predictive tool for structural integrity.
How do mare and highland simulants differ in mechanical response?
Highland simulants exhibit higher strength (5.79 MPa) and ductility (peak strain 0.13) compared to mare simulants. Strain localization patterns also differ: highland samples show band-type or diffuse patterns, while mare samples show highly tortuous network-type bands.
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