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Additive manufacturing framework, and cost evaluation tool for use in the cis-lunar ecosystem, An
Purcell, David Paul
Purcell, David Paul
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2025
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Abstract
Manufacturing and construction on the lunar surface will heavily depend on lunar regolith. Regolith can serve as a feedstock in various additive manufacturing technologies to create equipment for use within lunar habitats. The costs associated with lunar additive manufacturing are influenced by both the printing location and the feedstock source. Therefore, there is a need for a method to predict costs for additive manufacturing during various operational stages. This thesis consists of two major topics related to lunar regolith. The first presents research on a terramechanics study on the excavation forces required to mine regolith for subsequent use in additive manufacturing. The second is the development of a comprehensive AM framework, complete with a custom-built Cost Estimation Tool (CET) model.
The terramechanics study describes experimental and analytical work, evaluating the effect of lunar agglutinates on bulk regolith simulant properties. Three predictive terramechanics models were employed to compare the predicted horizontal excavation forces to measured values in atmosphere and vacuum conditions. The introduction of agglutinates increased the excavation forces when measured during a shallow, vertical blade cut.
The AM framework developed in this thesis outlines the progression of AM usage through four stages, with each stage representing an increase in technological capability. The CET model improves modern AM costing tools by incorporating machine-specific parameters and simulation-driven design. Results show cost-per-part savings utilizing AM on the lunar surface when leveraging fully in-situ based feedstock compared to terrestrially based manufacturing and shipment of parts to the Moon. Furthermore, the AM framework illustrates the viability of ISRU-produced components, which have undergone minimal post-processing. This reduces the total cost of potential components such as building materials or rover equipment.
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