Lunar Manufacturing Systems and the Role of Additive Recycling Technologies

Author

• Camille A. Newman, University of MississippiFollow

Date of Award

Spring 5-6-2026

Document Type

Undergraduate Thesis

Department

Mechanical Engineering

First Advisor

Joanna Harrelson

Second Advisor

Denise Theobald Roberts

Third Advisor

Tyler Biggs

Relational Format

Dissertation/Thesis

Abstract

Renewed international interest in sustained lunar exploration has created a growing demand for technologies to support long-duration space exploration. Part of the recent Artemis missions and the Moon to Mars initiative is to improve key mission capabilities and fill critical gaps necessary to sustain lunar habitation. Waste management, recycling systems, and manufacturing systems have been identified as critical technologies that need further development before a sustained mission is possible. This thesis explores the feasibility of an additive manufacturing and recycling system designed to process plastic waste generated during extended lunar habitation. Initial research focused on existing manufacturing and recycling technologies which could easily be adapted to lunar environments. Additive manufacturing methods were primarily investigated due to their flexibility and ability to produce complex geometries without extra tooling. Selective Laser Sintering (SLS) was chosen because of its compatibility with a broad range of materials and stronger/more solid part production. A conceptual lunar recycling system was designed using the parameters and requirements outlined by NASA’s LunaRecycle Challenge. The proposed system incorporates automated preprocessing, printing, and postprocessing of end-products. This automation helps reduce expended crew time and potential safety hazards. Viability testing on the proposed mixed material feedstock was then conducted using a converted laser engraver. Preliminary testing had significant limitations, but the results confirmed the feasibility of using SLS technologies to produce mixed material recycled parts. Following successful testing, a small-scale prototype based on open-source hardware and software platforms was designed and built. The prototype is able to successfully mimic the movements of a full SLS 3D printer and will be able to provide controlled test samples. Overall, this research supports the potential for lunar-based recycling systems which will not only improve sustainability of lunar missions, but it could have positive impacts on terrestrial recycling technologies

Recommended Citation

Newman, Camille A., "Lunar Manufacturing Systems and the Role of Additive Recycling Technologies" (2026). Honors Theses. 3532.
https://egrove.olemiss.edu/hon_thesis/3532

Creative Commons License

This work is licensed under a Creative Commons Attribution 4.0 International License.