Gateway Earth ISRU: Manufacturing Mechanical Modules on the Moon

The Seventh Step in the Gateway Earth’s deep space access architecture is in-situ resource utilisation (ISRU) at lunar and planetary destinations within our Solar System. This is to enable easier mission return as well as uplift of material or manufacture of required (spare) parts and components which can be made out of local minerals. Doing so would enable Gateway Earth to reduce required supply of raw material from the Earth and thus keep to a lower energy budget for its resupply missions. This research explores the feasibility of using Laser Powder Bed Fusion (LPBF) for the additive manufacturing of lunar regolith simulants (LRS), aiming to support future lunar base construction. The primary objective is to optimize key process parameters, including laser power and scan speed, to enhance the mechanical properties and structural integrity of the fabricated components. Experimental results demonstrate that ceramic substrates improve powder spreading and final product density, with observed densities ranging from 2.27 to 2.70 g/cm³. These findings contribute to the development of ISRU strategies for sustainable lunar exploration, providing a foundation for constructing human habitats on the Moon.