In this activity, lunar regolith simulants were characterised based on their thermal behaviour, particle size distribution and composition, in order to inform the choice of consolidation method for functionally graded materials (FGMs) – powder characterisation results are provided in the 'conference paper' deliverable.

Firstly, an extensive literature review study (deliverable 'Literature Review') identified Digital Light Processing (DLP) and Spark Plasma Sintering (SPS) as promising consolidation techniques.

This study aimed to demonstrate the feasibility, use and functionality of carbon fibre-reinforced flexible epoxy (CFRFE) materials for self-deployable space structures (such as deployable tape-spring hinges) by designing, simulating, manufacturing, testing and correlating a classic (100% carbon fibre-reinforced plastic -rigid resin- CFRP) deployable tape-spring hinge and a CFRFE deployable tape-spring hinge and compare their mechanical and dynamic behaviours.

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The project aimed to establish a structured approach to an optimised part or component by applying Concurrent Design methods. It intended to incorporate all necessary disciplines and competencies that are required for a potential spacecraft part. Within the activity, advanced manufacturing included various novel techniques, not only additive manufacturing. It means that the Concurrent Design approach was developed for the engineering of units to be built with a broad range of advanced manufacturing technologies.

Despite the fact that Additive Manufacturing has evolved rapidly, the process presents more challenges compared to the conventional manufacturing technologies. Therefore, it was identified the necessity to establish for each individual machine a process route traceability in order to define the optimum process parameters and to ensure the process repeatability and reliability, combined with the machine capabilities and limitations, to meet the space industry requirements.

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Motivation: This study aimed to develop promising robotic fabrication methodologies for a fibre-based in-situ robotic fabrication process, for application in a lunar habitat as an alternative to existing additive manufacturing methodologies. Previous work has verified that fibre composite fabrication processes are capable of a high degree of automation and structural performance.