Enhancing economical lunar-based manufacturing by incorporating lunar regolith into polyether-ether-ketone (PEEK): material development, additive manufacturing, and characterization

Humankind is preparing for extended space exploration and settlement. In-space manufacturing (ISM) is pivotal for prolonged space missions, with additive manufacturing (AM) showing particular promise. Polyether ether ketone (PEEK) is a highly suitable thermoplastic polymer for Lunar conditions. Integration of Lunar regolith into PEEK has the potential to lower ISM expenses. This research presents materials extrusion AM of PEEK/30 wt% regolith composites and compares them with pure PEEK. Regolith content poses challenges during extrusion, resulting in increased sample porosity. Including 30 wt% Lunar regolith decreases tensile strength by 27%. Microstructural analyses reveal a random distribution of regolith particles in the PEEK matrix, showcasing the efficacy of the mixing strategy. In addition, they depict the presence of pores in both PEEK/regolith filament and sample. On the other hand, bonding within the layers improved with the presence of regolith. These findings carry significant implications for advancing AM within Lunar environments and ISM endeavors.