A Virtual 3D Printing Framework for Off-Earth Construction

3D printing, due to its digital nature, offers a practical approach to autonomous off-Earth construction by utilizing local materials, thereby reducing the reliance on Earth-based resources and manpower. Implementing large-scale and rapid 3D printing of structures in extraterrestrial environments poses unique challenges due to conditions such as altered gravity, vacuum, and extreme thermal variations. These challenges are compounded by the fact that replicating altered gravity on Earth is not feasible. Therefore, a virtual system is needed to advance the 3D printing capabilities. This paper presents computational fluid dynamics (CFD) models developed to simulate the 3D printing of structures under altered gravity conditions. The results provide insights into geometrical precision and deformation as gravity varies across different celestial bodies, as well as the influence of regolith mortar properties and nozzle diameter when focusing on printing on the Moon. The results highlight ways to control the curing kinetics of the Lunar regolith mortar in order to print fast and on larger scale.