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Laser-Based 3D Printing Could Build Future Bases on the Moon
Through the Artemis Program, NASA hopes to establish a permanent human presence on the Moon in its southern polar region. China, Russia, and the European Space Agency (ESA) have similar plans, all of which involve building bases near the permanently shadowed regions (PSRs) – i.e., craters that contain water ice – that dot the South Pole-Aitken Basin. For these and other agencies, it is vital that these bases be as self-sufficient as possible since resupply missions cannot be launched regularly and take several days to arrive.
Therefore, any plan for a lunar base must come down to harvesting local resources to meet the needs of its crews as much as possible – a process known as In-Situ Resource Utilization (ISRU). In a recent study, researchers at The Ohio State University (OSU) proposed using a specialized laser-based 3D printing method to turn lunar regolith into hardened building material. According to their findings, this method can produce durable structures that withstand radiation and other harsh conditions on the lunar surface.
The research team was led by Sizhe Xu, a Graduate Research Associate at OSU. He was joined by colleagues from OSU’s Department of Integrated Systems Engineering, Mechanical and Aerospace Engineering, and Materials Science & Engineering. Their paper, “Laser directed energy deposition additive manufacturing of lunar highland regolith simulant,” appeared in the journal Acta Astronautica.
*Cutaway image of a lunar habitat. Credit: ESA*
The importance of ISRU for human exploration has prompted the rapid development of additive manufacturing systems – aka 3D printing. These systems have proven effective at fabricating tools, structures, and habitats, effectively reducing dependence on supplies delivered from Earth. Developing such systems for long-duration missions is one of the most challenging aspects of the process, as they must be engineered to operate in the extreme environment on the Moon. This includes the lack of an atmosphere, massive temperature variations, and the ever-present problem of Moon dust.
Scientists use two types of lunar regolith for their experiments and research: Lunar Highlands Simulant (LHS-1) and Lunar Mare Simulant (LMS-1). As part of their research, the team used LHS-1, which is rich in basaltic minerals, similar to rock samples obtained by the Apollo missions. They melted this regolith with a laser to produce layers of material and fused them onto a base surface of stainless steel or glass. To assess how well these objects would fare in the lunar environment, the team tested their fabrication process under a range of different environmental conditions.
One thing they noticed was that the fused regolith adhered well to alumina-silicate ceramic, possibly because the two compounds form crystals that enhance heat resistance and mechanical strength. This revealed that the overall quality of the printed material is largely dependent on the surface onto which the regolith is printed. Other environmental factors, such as atmospheric oxygen levels, laser power, and printing speed, also affected the stability of the printed material. As Xu explained in an OSU News release:
By combining different feedstocks, like metal and ceramics, in the printing process, we found that the final material is really sensitive to the environment. Different environments lead to different properties, which directly affect the mechanical strength and the thermal shock resistance of certain components. There are so many applications that we’re working toward that with new information, the possibilities are endless.
*Astronauts collecting samples on the lunar surface as part of NASA’s Artemis Program. Credit: NASA*
Deployed to the Moon’s surface, this process could help build habitats and tools that are strong, resilient, and capable of handling the lunar environment. This has the added benefit of increasing independence from Earth, which is key to realization long-duration missions on the Moon. In addition to assisting astronauts exploring the Moon in the near future (as part of NASA’s Artemis Program), this technology could also lead to resilient habitats that will enable a long-term human presence on the Moon, Mars, and beyond.
However, there are several unknown environmental factors that could limit the effectiveness of these systems on other worlds, and more data is needed before they can be addressed. In their study, the team suggests that instead of being powered by electricity, future scaled-up versions of their method could rely on solar or hybrid power systems. Nevertheless, the potential for space exploration is clear, and the technology also has applications for life here on Earth. Sarah Wolff, an assistant professor in mechanical and aerospace engineering and a lead author on the study, explained:
There are conditions that happen in space that are really hard to emulate in a simulant. It may work in the lab, but in a resource-scarce environment, you have to try everything to maximize the flexibility of a machine for different scenarios. If we can successfully manufacture things in space using very few resources, that means we can also achieve better sustainability on Earth. To that end, improving the machine’s flexibility for different scenarios is a goal we’re working really hard toward.
As the saying goes, “Solving for space solves for Earth.” In environments where materials and resources are limited, laser-based 3D printing is one of several technologies that could support sustainable living. This applies equally to extraterrestrial environments and to regions on Earth experiencing the effects of Climate Change.
Further Reading: OSU
News
What Happens When Light Goes Boom? Part 1: The Scientist Who Stared at a Glow
I want you to imagine a scene. It’s the red carpet. It’s the night of the Oscars, or the Emmys, or the participation trophy ceremony for your kid’s soccer team. That’s not the essential part of the metaphor. What matters is who is there: Brad Bradington’s adoring fans, curious onlookers, and of course the paparazzi, ready to take their shot.
In our analogy, Brad Bradington is a particle. An electron, a proton, even a neutrino if it felt like it. The crowd of onlookers and fans? That’s a material — a substance, like air or water or diamond or the inside of your eyeball (which is mostly water and hopefully very little diamond).
And those paparazzi? They’re the most important part.
I’m talking today about something called Cherenkov radiation, which I prefer to call a “light boom” but as usual nobody listens much to me. We’ll get to Brad Bradington and his red carpet moment. But first we need to talk about the man who stared at a faint blue glow for three years and refused to look away.
It’s 1934. Pavel Alekseyevich Cherenkov is working in Moscow, doing the kind of science that sounds almost embarrassingly simple when you describe it at a party: he’s shining gamma rays into a bottle of water.
That’s it. That’s the whole experiment.
Hey — in the 1930s, a lot of particle physics involved shining or shooting X into target Y, so it’s not as lame as it sounds. But still. A bottle of water.
And when he shoots the gamma rays into the water, it glows. Blue. Faint, barely there. But unmistakably there.
Now here’s the thing. This wasn’t the first time anyone had seen this. Marie Curie’s lab had noticed the same glow years earlier. Other physicists had seen it too. And every single one of them had looked at it, shrugged, and written it off as fluorescence — some impurity in the water absorbing the radiation and re-emitting it as light. Secondary effect. Not interesting. Move along.
Cherenkov looks at it and thinks the great hallmark of most scientific discoveries: huh, that’s weird.
It’s said that good scientists don’t discover new things — they look at old things in a new way. Pavel did that.
He’s not sure why he’s suspicious. But he’s suspicious. So he does what any good experimentalist does when something doesn’t sit right — he starts poking it. He tries purifying the water. The glow stays. Hmm. He tries different liquids. The glow changes. Ooh! He varies the energy of the radiation. The glow responds. Neat! He changes the geometry of the experiment.
The glow has a direction.
Wait, what?
Fluorescence glows in all directions equally — it doesn’t care which way you’re looking at it. But this glow was asymmetric. It was stronger in some directions than others. It was doing something fluorescence absolutely does not do.
He doesn’t know what this is. But this is definitely NOT fluorescence.
So Cherenkov does something that separates the great scientists from the merely good ones: he decides that not knowing what something is is not a reason to stop looking at it. He spends the next three years characterizing this phenomenon with almost obsessive precision. He’s not a theorist — he can’t tell you WHY it’s happening. But he can tell you everything about WHAT it’s doing. He measures its intensity, its direction, its dependence on the speed of the incoming particles, its behavior in different materials. He builds up a complete empirical portrait of something he fundamentally doesn’t understand.
He publishes his results. The physics community is…mildly interested. This is the 1930s. There’s a lot going on. Quantum mechanics is still being sorted out. Nuclear physics is exploding — literally. A faint blue glow in a bottle of water is not exactly front page news.
A few years later, a pair of theorists pick up his careful measurements and figure out what’s actually going on.
It’s Brad Bradington, showing up at the red carpet.
In Part 2, we need to talk about the crowd — and why the speed of light is not actually a universal speed limit.
News
Hundreds of affordable housing units funded by new L.A. County agency

For Michael Miller, getting a project off the ground is usually a bureaucratic juggling act.
When building affordable housing like the 200-plus units he’s planning in Harbor Gateway and Stevenson Ranch, the president of Bold Communities said he’d typically be forced to find funding through three to five different local and state agencies.
This time around, he’s going to just one: the newly established L.A. County Affordable Housing Solutions Agency.
The agency, known as LACAHSA, bills itself as a one-stop shop for affordable housing financing with offers of construction loans, permanent loans, rental subsidies and other types of funding products. It’s betting that in doing so developers can build low-income homes quicker and cheaper in a county with a bruising affordability and homelessness crisis.
There’s some evidence this is the case. According to the Terner Center at UC Berkeley, each additional public funding source an affordable developer uses, on average, delays a project four months and increases total cost by $20,460 per unit — more than $2 million for a 100-unit community.
“We want to build housing cheaper and quicker, because that means more units,” LACAHSA interim chief executive Ryan Johnson said.
On Wednesday, the agency gave approval to just over $100 million for ten projects, including the two from Bold Communities.
The Terner Center said going to multiple agencies for needed funding adds costs because developers have to endure higher legal, staffing and compliance costs to manage additional applications and contracts.
Each process, of course, also takes time, during which developers pay additional holding costs on predevelopment loans, all the while inflation pushes up the cost of materials and wages.
Miller estimated by going through only LACAHSA, he could cut down total costs around 5% to 10%.
LACAHSA, founded through state legislation in 2022, receives its funding from the recent voter-approved Measure A half-cent sales tax to fight homelessness and build affordable housing.
Until now, the agency had awarded money only for homeless prevention efforts such as direct rental subsidies to tenants.
It’s first batch of funds to build and preserve affordable housing, approved Wednesday, will pay for 554 below market units. The vast majority will be brand new homes, while a small share will be conversions of existing market rate residential units into affordable units and extending deed-restrictions on some existing below-market units.
LACAHSA pointed to data showing that of the top performing quarter of new construction projects that recently applied for its funding, total development costs came in below the typical cost to build affordable units in the county. Savings rose to nearly 12% when project proposals relied primarily or entirely on LACAHSA funding, rather than mixing state funding with just one or two LACAHSA products.
Terner Center managing director Ben Metcalf said it’s unclear to what extent those savings might reflect that cheaper projects just happened to apply for funding from LACAHSA. But he expects at least some of the savings can be attributed to LACAHSA’s structure.
Not only does the agency offer a plethora of financial products, but LACAHSA said it ranks project proposals by their efforts to reduce costs and considers that as a significant factor when deciding to approve funding.
Metcalf, who previously served as director of the California Dept. of Housing and Community Development, said such a focus on awarding dollars based on the estimated development cost isn’t the norm among public agencies.
In part, he theorized that was because “the rising cost of affordable housing has really only become an issue of visible concern over the last few years.”
In 2022, the Times reported the cost to build just one unit of affordable housing in California routinely cost more than $1 million. Voters have also expressed growing frustration at the lack of progress in reducing homelessness and overall housing costs.
LACAHSA isn’t the only effort to simply a complicated funding process, with Gov. Gavin Newsom proposing to streamline state funding as part of this year’s budget.
Meanwhile, LACAHSA plans to approve another round of affordable housing funds in May.
To apply for that funding and the dollars approved Wednesday, LACAHSA said it required developers to be able to break ground within 12 months. Developers submitted 127 applications, seeking a total of $1.5 billion to build 11,625 units.
Long Beach Mayor Rex Richardson, who serves as chair of the LACAHSA board, argued the high interest shows it’s really a lack of “financing and operational support” holding back the construction of more affordable housing in L.A. County, rather than a lack of “sites or community will.”
“LACAHSA was built to meet this moment,” he said in a statement.
The projects that Bold Communities plans in Harbor Gateway and Stevenson Ranch are conversions of extended stay hotels into low-income senior housing.
Now that funding is secured, Miller said he expects the buildings to be full of new residents by the end of next year.
“I think these will be, honestly, pretty straight forward,” the non profit executive said.
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