One of the key challenges for future missions to other planets, e.g. Mars, is the synthesis of structural and functional materials. The limited amount of space on space ships, as well as the high price per cargo unit, results in the need for on-site structures from available resources (ISRU). Several works have shown the possibility of obtaining metals, in particular iron in powder form from the regolith present in large quantities on Mars and the Moon. Iron is a promising structural material as it features good mechanical properties, but the production of pure metals is energy inefficient. Metal matrix composites (MMC's) are a possible alternative material to reduce energy costs. Regolith – soil that can be found on Mars and Moon with complex chemical and phase composition, could be used as a composite filler that would maintain the material's properties at the same time as reducing energy costs. In the production of functional parts, additive manufacturing techniques have been used to eliminate the need for additional post-processing steps in production of more complex parts.

In this work, water atomized iron and Martian regolith simulant were mixed together and processed by laser powder bed fusion (L-PBF).  The effects of different sizes, fill volumes of regolith particles and printing regimes on material properties have been investigated. Structural and chemical analysis of the material and initial mechanical tests were carried out. The promising results show the potential of implementation this technology in future interplanetary missions and using this technology in regions with limited resources.  The next stage of the research will involve the use of 'impure' materials that are closer to the materials that can be obtained on Mars.