Additive Manufacturing of Lunar Regolith: A Review

Abstract

Lunar in-situ construction using additive manufacturing (AM) technology has emerged as a critical pathway for sustainable extraterrestrial exploration. This review systematically evaluates two dominant AM paradigms for lunar regolith processing: low-temperature deposition forming (material extrusion and binder jetting), and high-energy beam additive manufacturing (powder bed fusion and directed energy deposition). Low-temperature methods achieve moderate compressive strength with low energy consumption but face challenges such as binder dependency and vacuum instability. By contrast, high-energy beam techniques enable binder-free fabrication with better compatibility for in-situ resource utilization, though they suffer from porosity, high energy intensity, and geometric limitations. In the context of lunar in-situ resource utilization (ISRU), low-temperature methods offer near-term feasibility for small-scale infrastructure, while high-energy approaches show promise for large-scale, autonomous construction by leveraging solar energy and raw regolith. Future advancements will hinge on hybrid systems that integrate material efficiency, energy sustainability, and robotic adaptability to overcome extreme environmental challenges. This review consolidates technological progress, identifies interdisciplinary synergies, and provides strategic insights into guiding the transition from Earth-dependent prototypes to self-sufficient lunar habitats, ultimately advancing the capability of humanity for a long-term extraterrestrial presence.