Research

This research evaluated the feasibility of using direct Concentrated Solar Power (CSP) via a 961x Fresnel lens to process materials for lunar In-Situ Resource Utilization (ISRU), bypassing photovoltaic energy conversion losses. Outdoor experimental testing combined with 3D transient thermal Finite Element Analysis (FEA) in SolidWorks revealed that while bulk aluminum acts as a heat sink (capping at ~435°C), low-mass aluminum wire reached ~600°C and became hyper-malleable. Additionally, direct solar flux successfully vitrified lunar regolith simulant at ~750°C into solid ceramic glass for habitat and infrastructure construction.  

To capitalize on these findings, the study proposed a Solar Wire Deposition & Hot-Forming System. Rather than attempting to melt static metal blocks, an automated mechanism continuously feeds aluminum wire into the optical focal spot to deposit softened beads layer-by-layer. Integrated mechanical rams then forge the plasticized metal into structural components under closed-loop temperature, force, and displacement sensor feedback, establishing an efficient framework for lunar metal 3D printing.