Purdue University researchers published a comprehensive review in the journal npj Advanced Manufacturing that identifies powder-based additive manufacturing as a viable route to produce tools, habitats, and infrastructure directly in space. The review highlights two feedstock streams: lunar regolith, with about 90% of particles smaller than 1,000 micrometers, and recycled orbital debris, with an estimated 9,500 tons of metal in orbit, including roughly 40,500 objects larger than 10 centimeters, about 1.1 million fragments between 1 and 10 centimeters, and more than 130 million pieces smaller than 1 centimeter.
The technical implication is decisive: space manufacturing can shift from Earth-supplied filament and stock to local and orbital matter, which is the foundation for autonomous lunar industry. The paper says electrolysis is the most space-compatible powder-production method because it works without gravity, can run on solar power, and can use local water or metal-rich regolith; it also flags chemical reduction as feasible where metal oxides and reducing agents are available. That means future lunar bases could fabricate replacements, radiation shielding, structural panels, and habitat components on demand, reducing resupply risk across multi-year missions.
Ark priority: monitor powder control, feedstock characterization, and debris-to-powder conversion methods, because these are the bottlenecks between concept and resilient lunar manufacturing. The review specifically points to robotic debris capture, sorting by laser-induced breakdown spectroscopy or X-ray fluorescence, atomization into printable metal powder, and characterization methods such as dynamic image analysis and electrical sensing zone measurement under microgravity. The Ark should treat this as a candidate pathway for closed-loop lunar industry and debris remediation, but not as mature infrastructure until microgravity powder handling, contamination control, and long-duration reliability are demonstrated.