3D space printing turns Mars dust into rocket parts

However, with the support of 3D space printing technology, all this will change. 3D printing can make almost anything in space when needed.

In 2014, the American company Made In Space sent a 3D printer to the ISS for the first time, and it was used to demonstrate that parts printed in microgravity were as strong as those printed on Earth.

After years of development, today, 3D printing has been able to print Martian dust into rocket parts. According to researchers at Washington State University, a small amount of simulated crushed Martian rock was mixed with a titanium alloy to create a stronger, higher-performance material in a 3D printing process that could be used to make tools and rockets to explore the Red Planet part. This breakthrough could make future space travel cheaper and more practical.

To do this, the researchers tested Martian rock dust (regolith). This is a black powdery substance used to simulate rocky material found on the surface of Mars, collected by the robotic arm of the Mars rover. The researchers mixed simulated Martian rock dust with a titanium alloy using a powder-based 3D printer. Titanium alloys are commonly used in space exploration due to their heat resistance and strength.

The researchers used high-power lasers to heat the materials to more than 2,000 degrees Celsius to melt them. Then, pouring the molten mixture onto a moving platform allows the researchers to create different sizes and shapes. After the material cooled, the researchers tested its strength and durability.

Among them, the researchers used Martian regolith in proportions ranging from 5% to 100% in the printing. Parts made with just 5% of Martian regolith without any cracks or air bubbles performed better and were stronger than titanium alone. This means it can be used to make lighter weight parts and still withstand heavy loads. While objects made of 100% regolith are more prone to cracking and lack strength, the material can nonetheless be used to make coatings to protect equipment from rust or radiation damage.

This innovation could make it possible to make parts directly on Mars, and perhaps, in the not too distant future, creating anything on demand with a “replicator” will become a unique experience in interstellar travel.