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Influence of Powder Type on Aerosol Emissions in Powder-Binder Jetting with Emphasis on Lunar Regolith for In Situ Space Applications
Abstract
Abstract Powder-binder jetting is an additive process with applications for manufacturing complex geometric structures, such as lightweighting, mold making, and in situ resource utilization (ISRU) for space applications. With this technique, a powder feedstock is spread across a bed during which aerosol may be released leading to human health implications. This study characterizes airborne powder emissions for three powders of varying particle diameters and composition: Hydroperm gypsum plaster, Lunar Highland Simulant regolith (LHS-1, a lunar soil simulant), and Zeolite 13X (a molecular sieve). Bulk powder D50 values were 22 μm for Hydroperm, 304 μm for LHS-1, and 3.85 μm for Zeolite. Total particle emission rates were (5.4 ± 0.96) × 105 min–1 for Hydroperm, (1.0 ± 0.28) × 106 min–1 for Zeolite, and (2.2 ± 0.82) × 107 min–1 for LHS-1. An emission factor was developed normalized to the volume of powder spread resulting in emission factors of 2.8 ± 0.85 min–1 mm–3 for Hydroperm, 220 ± 72 min–1 mm–3 for LHS-1, and 5.0 ± 0.24 min–1 mm–3 for Zeolite. This indicates that particle emissions from powder-binder jetting machines with a constant spreading mechanism can vary widely depending solely on powder type. In the experimental enclosure where testing took place, LHS-1 PM10 concentrations exceeded 8 h TWA PEL OSHA standards for crystalline silica by sixfold, indicating that air quality should be a strong design consideration for 3D printing for lunar ISRU. With lower gravitational settling effects, Lunar particulate concentrations 20 m away from the printer were modeled to be 330% higher than on Earth. This study suggests that powder size, morphology, and composition should be considered holistically when determining emission concerns for new powders in powder-binder jetting. This study also suggests particular attention should be paid to aerosol emissions in a Lunar environment.
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Given Lunar microgravity, particulate concentrations at 20 m from the printer can be up to 330% higher compared to Earth conditions.
“Given the Lunar microgravity environment, their study predicted that particulate concentrations at a distance of 20 m from the printer can be up to 330 % higher compared to Earth conditions.”
From A comprehensive review of lunar-based manufacturing and construction (2024) · cites this paper as [300]
Hayes et al. found variations in particle emissions during binder jetting primarily depend on the type of powder used.
“Their findings indicated that variations in particle emissions during the binder jetting process primarily depend on the type of powder used, emphasizing the importance of considering air quality as a design factor for printing processes.”
From A comprehensive review of lunar-based manufacturing and construction (2024) · cites this paper as [300]
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Metadata
- Authors
- Hayes, A. C., Osio-Norgaard, J., Miller, S., Vance, M. E., & Whiting, G. L.
- Affiliations
- University of Colorado Boulder (US)
- University of Colorado Boulder , , , ,
- Corresponding author
- Vance, Marina E.
- Whiting, Gregory L.
- Venue
- ACS ES&T Engineering
- Publisher
- American Chemical Society (ACS)
- Published
- 2020-10-05
- Volume
- 1
- Issue
- 2
- Pages
- 183-191
- ISSN
- 2690-0645 (ISSN-L)
- OpenAlex
- W3092649147
- Cited by
- 14
- References
- 30
- Citations by year
- 2026: 3 · 2025: 4 · 2024: 3 · 2022: 2 · 2021: 2
- FWCI
- 0.49
- Type
- journal article
- Language
- en
- Open access
- closed
- Licence
- Locations
- ACS ES&T Engineering (publishedVersion)
- CU Scholar (University of Colorado Boulder) (submittedVersion)
- Funders
- University of Colorado Boulder
- National Science Foundation (DGE 1650115)
- Topics
- Physical Sciences › Engineering › Mechanical Engineering › Additive Manufacturing Materials and Processes
- Physical Sciences › Environmental Science › Health, Toxicology and Mutagenesis › Air Quality and Health Impacts
- Physical Sciences › Engineering › Industrial and Manufacturing Engineering › Additive Manufacturing and 3D Printing Technologies
- Keywords
- aerosol emissions, lunar regolith simulant, in-situ resource utilization, particle emission rate, emission factors, PM10, crystalline silica exposure, gypsum plaster, zeolite 13X, powder particle size
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