3D Printing of Batteries from Lunar and Martian Regolith
Authors: Maurel Alexis , Martinez Ana Cristina , Cortes Pedro , Yelamanchi Bharat , Chavari Sina Bakhtar , Sreenivasan Sreeprasad T , Sherrard Cameroun , MacDonald Eric 
Published: September 2023

To maximize the sustainability of future space missions, the utilization of local resources available on the Moon or Mars, also known as in-situ resource utilization (ISRU), is crucial to develop infrastructures such as habitation modules, power generation, and energy storage facilities.1–3 This work presents a perspective aiming to introduce the future of batteries manufacturing on the lunar and martian environment from ISRU materials. Based on the composition of the lunar and martian soil,4–7 the choice of the battery technology and materials for the different battery components (electrodes, electrolyte, current collectors and packaging) are examined. The motivations for selecting additive manufacturing technologies as a unique approach to support human operations in space, on the surface of the Moon or Mars, and any other locations where cargo resupply is not as readily available, as well as the need for high resolution multi-material printing methods, are discussed. Additive manufacturing paves the way to three-dimensional rechargeable battery architectures with enhanced specific surface area, three-dimensional ion diffusion, and improved power performances, while also allowing the development of shape-conformable batteries to maximize the energy storage within the final application.8–15 The in-space additive manufacturing process of shape-conformable batteries using in-situ resources is in direct alignment with the NASA’s objectives to demonstrate in-space autonomous manufacturing and assembly of complete systems by 2030, and to enable Humans survival, explore deep space, and visit planetary surfaces by 2040.16 Such initiatives also contribute to reducing power-related payload weight and volume in future missions, thus reducing the risk for long term Moon or even Mars missions where rapid resupply will be logistically infeasible. In this context, this presentation will provide a perspective of what is required to 3D print batteries on lunar and martian surfaces,17 an overview of our ongoing project dedicated to AM of sodium-ion batteries from resources available on the Moon and Mars and our recent work on 3D printing of TiO2 negative electrode material by means of the vat photopolymerization process.18

(1) Anand, M. et al. A Brief Review of Chemical and Mineralogical Resources on the Moon and Likely Initial in Situ Resource Utilization (ISRU) Applications. Planet. Space Sci.
2012, 74 (1), 42–48.
(2) Edmunson. Building a Sustainable Human Presence on the Moon and Mars. New Horizons Summit.
(3) McMillon-Brown, L. et al. What Would It Take to Manufacture Perovskite Solar Cells in Space? ACS Energy Lett.
2022, 7 (3), 1040–1042.
(4) Heiken, G. et al. Lunar Sourcebook: A User’s Guide to the Moon; CUP Archive, 1991.
(5) Dreibus, G. et al. Lithium and Halogens in Lunar Samples. Philos. Trans. R. Soc. Lond. A
1977, 285 (1327), 49–54.
(6) Taylor, G. J. The Bulk Composition of Mars. Geochem. Explor. Environ. Analy.
2013, 73 (4), 401–420.
(7) Yoshizaki, T. et al. The Composition of Mars. Geochim. Cosmochim. Acta
2020, 273, 137–162.
(8) Maurel, A. et al. Highly Loaded Graphite-Polylactic Acid Composite-Based Filaments for Lithium-Ion Battery Three-Dimensional Printing. Chem. Mater.
2018, 30 (21), 7484–7493.
(9) Maurel, A. et al. Considering Lithium-Ion Battery 3D-Printing via Thermoplastic Material Extrusion and Polymer Powder Bed Fusion. Additive Manufacturing
2020, 101651.
(10) Martinez, A. C. et al. Additive Manufacturing of LiNi1/3Mn1/3Co1/3O2 Battery Electrode Material via Vat Photopolymerization Precursor Approach. Sci. Rep.
2022, 12 (1), 1–13.
(11) Maurel, A. et al. Overview on Lithium-Ion Battery 3D-Printing By Means of Material Extrusion. ECS Trans.
2020, 98 (13), 3–21.
(12) Maurel, A. et al. Toward High Resolution 3D Printing of Shape-Conformable Batteries via Vat Photopolymerization: Review and Perspective. IEEE Access
2021, 9, 140654–140666.
(13) Maurel, A. et al. Ag-Coated Cu/Polylactic Acid Composite Filament for Lithium and Sodium-Ion Battery Current Collector Three-Dimensional Printing via Thermoplastic Material Extrusion. Frontiers in Energy
Research
2021, 9 (70). https://doi.org/10.3389/fenrg.2021.651041.
(14) Ragones, H. et al. Towards Smart Free Form-Factor 3D Printable Batteries. Sustainable Energy & Fuels
2018, 2 (7), 1542–1549.
(15) Egorov, V. et al. Evolution of 3D Printing Methods and Materials for Electrochemical Energy Storage. Adv. Mater.
2020, 32 (29). https://doi.org/10.1002/adma.202000556.
(16) Murphy, P. STMD’s New Strategic Framework Update, 2017. https://www.nasa.gov/sites/default/files/atoms/files/336429-508-to5_nac_dec_2017_strategicplanningintegration_tagged.pdf.
(17) Maurel, A. et al. What Would Battery Manufacturing on the Moon and Mars Look Like? (submitted).
(18) Maurel, A. et al. 3D Printed TiO2 Negative Electrodes for Sodium-Ion and Lithium-Ion Batteries Using Vat Photopolymerization (submitted).