The FFLD project explores fibre-reinforced additive manufacturing using lunar regolith as part of ESA’s Off-Earth Manufacturing initiative. Building on the Fused Layer Deposition (FLD) process, FFLD introduces embedded fibres into molten regolith to enhance the mechanical performance of glassy printed structures. While thermal incompatibilities and brittle behavior limited direct fibre integration, the research expanded into alternative fibre-based strategies, including fibre-imprinted casting, hybrid reinforcement systems, and recycling fractured composites. The project establishes a technology roadmap for structurally efficient, multifunctional lunar components, contributing to scalable and resource-autonomous construction on the Moon.

ESA DISCOVERY CNo. 4000141391