In-depth analysis of sintering, exposure time, and layer height (um) in LRS 3D printed devices with DLP

Abstract

The technology of 3D printing, referred to as additive manufacturing, is widely acknowledged as a transformative innovation that has the potential to supplant traditional processing methods in numerous domains. The present study showcases a quantitative assessment of the mechanical properties of moon dust, also known as Lunar Regolith Simulants (LRS), printed through vat polymerization. In this study, we conduct a thorough investigation and explore the effects of layer height [L_H] (L_H = 10 μm, 20 μm, 30 μm, 40 μm, 50 μm, 60 μm]), exposure time [E_T] (E_T = 3000 ms, 5000 ms, 7000 ms, 11,000 ms), and sintering impact [1075 °C, 1082 °C, 1083 °C, 1085 °C, 1086 °C, 1087 °C, 1090 °C] on the mechanical properties of printed structures. Herein, we utilize a 55 % volume suspension of LRS to print rod and block configurations via digital light printing [DLP] that are subsequently consolidated through sintering in ambient air. This 55 % LRS via vat polymerization approach has not been previously reported. The morphology of the simulant powders exhibited irregular and angular features. Our experimental results show that a 30 um (L_H) with (E_T) 11,000 ms exhibits maximum compressive and flexural strength of 330 MPa and 100 MPa at 1085 °C. The sintering atmosphere greatly affects the microstructure, macroscopic features, and mechanical strength of 3D-printed LRS, which reveals diverse chemical compositions and underlying reaction mechanisms. This sintering process improves particle bonding, resulting in densification and reduced voids within the 3D-printed structure. It is essential to optimize the annealing parameters to achieve the desired strength while avoiding excessive sintering that may cause dimensional distortions or structural defects. This innovative approach opens new possibilities for future space exploration and extraterrestrial construction.