Ohio State Researchers Use Lasers to 3D Print Structures From Moon Dust

On the Moon, nothing is easy to replace. Every tool, spare part and structural component must be launched from Earth, with a very high price tag. The solution, researchers from The Ohio State University believe, may be hiding in the dust beneath astronauts' boots.

This dust has a name: lunar regolith, a loose layer of fragmented rock built up over billions of years of meteorite impacts. It is abundant and non-toxic, making an obvious candidate for in-situ manufacturing. When every kilogram launched from Earth costs a fortune, building with locally available material stops being an interesting idea and starts being a necessity.

Why Laser Directed Energy Deposition?

The next question is how to process it. Several additive manufacturing techniques have already been tested with lunar regolith simulants, but most come with a catch. Laser Powder Bed Fusion requires large powder beds and Binder Jetting needs chemical binders. But when your factory has to fit inside a spacecraft, that quickly becomes impractical.

Laser Directed Energy Deposition (LDED) offers a solution. It feeds regolith directly into a laser melt pool, behaving more like a robotic welder than a traditional 3D printer. That distinction matters. LDED can build onto existing surfaces and repair damaged structures in place, not just manufacture new parts inside a confined chamber. On a lunar base, where a cracked component could be catastrophic, that capability is not a minor detail.

Turning Moon Dust into Building Material

The study, published in Acta Astronautica, put LDED through its paces with LHS-1, a lunar highland regolith simulant. Researchers tested different atmospheres, laser powers and scanning speeds to understand how each variable affected adhesion, porosity and microstructure.

A significant finding was a phase transformation. Under the right conditions, the regolith converted into mullite, a ceramic known for its thermal stability and mechanical strength. These are exactly the kind of properties you want for any structure built to survive on the Moon. But the window to achieve it is narrow: a 64 W laser at 6 mm/s produced the most stable results. What you print on matters too. Alumina-silicate ceramic substrates produced strong layer bonding, while stainless steel and glass both failed during cooling.

The Path Forward

None of this is ready for the Moon just yet. The research is still at laboratory scale. But the findings contribute to the development of manufacturing systems designed for extreme and resource-limited environments.

The timing matters too. NASA's Artemis program is pushing toward a sustained human presence on the Moon later this decade. If humans are going to live and work on the lunar surface, they'll need to build — and the materials to do it may already be under their feet.