Research Project
Additive Manufacturing of Sulfur Concrete for Mars Habitats
Research Team
Lead Researchers:
-
Dr. C. Shawn Sun, Department of Civil Engineering and Management
Collaborators:
- Jeffrey M. Megivern, JPL
Student Team:
- Nikhil Sagar Dadem
- Ankeen Arestakesyan
- Guy Greeff
- Carla Jimenez
- Rene Montelongo
Funding
- Funding Organization:
- Funding Program:
Abstract
This research project explores the viability of 3D printing Martian habitats using sulfur-based concrete, a material compatible with the resources available on Mars. The work focuses on modifying a large-scale concrete 3D printer, optimizing print consistency, and refining sulfur concrete mixtures suitable for Martian conditions. Progress includes mechanical upgrades to the gantry printer, experimental mix designs for layer adhesion and pumpability, and the development of an automated Z-lowering system to simulate vertical movement during printing.
Motivation/Research Problem
Research Objectives
-
Evaluate the feasibility of 3D printing Mars habitats using sulfur concrete.
-
Design and assemble a gantry-style 3D printer customized for concrete extrusion.
-
Optimize concrete mix designs (flowability, set time, interlayer adhesion).
-
Address mechanical challenges related to concrete extrusion, such as flow consistency and Z-axis movement.
-
Transition from water-based concrete printing to sulfur-based printing using a heated pump system.
Research Methods/Approach
-
Assemble and modify a large-format gantry 3D printer based on Marlin firmware.
-
Design and fabricate a custom auger-based concrete pump with air compressor integration.
-
Test various print setups to address flow restrictions, including air-tightness, tube bends, and system pressurization.
-
Document and iterate on weekly concrete mixture trials, refining parameters including cement-to-water ratio, superplasticizer dosage, and use of non-shrink grout.
-
Implement a mechanical lowering system using synchronized car jacks controlled by stepper motors to address the fixed height of the extruder.
-
Explore and compare practices from existing academic concrete printing systems to improve print quality and material performance.
Research Results and Deliverables
-
Fully assembled and operational concrete 3D printer with custom auger pump system.
-
Repeated successful test prints reaching five or more consistent layers.
-
Functional mechanical Z-lowering system to simulate nozzle elevation.
-
Documented weekly concrete mix ratios and corresponding print results.
-
Evaluated mixture behaviors for varied water and 2040 RM superplasticizer levels.
-
Identified that rotor stator pumps used in industry may offer better pressure delivery, though currently cost-prohibitive.
-
Initial training video documentation of the concrete mixing and printing process.
-
Preparation for sulfur-based printing by exploring heated pumping systems and replacement of components for high-temperature durability.
Research Timeline
Start Date:
End Date:
Acknowledgements
This work is supported by the NASA-funded ARCS program. Special thanks to Dr. C. Shawn Sun for his ongoing guidance, and the CSUN Department of Civil Engineering and Construction Management for their resources and mentorship.
Lead Researchers:
-
Dr. C. Shawn Sun, Department of Civil Engineering and Management
Collaborators:
- Jeffrey M. Megivern, JPL
Student Team:
- Nikhil Sagar Dadem
- Ankeen Arestakesyan
- Guy Greeff
- Carla Jimenez
- Rene Montelongo
Funding
- Funding Organization:
- Funding Program: