The return to the Moon is an important short-term goal of NASA and other international space agencies. To minimize mission risks, technologies, such as rovers or regolith processing systems, must be developed and tested on Earth using lunar regolith simulants that closely resemble the properties of real lunar soil. So far, no singular lunar simulant can cover the multitude of use cases that lunar regolith involves, and most available materials are poorly characterized. To overcome this major gap, a unique modular system for flexible adaptable novel lunar regolith simulants was developed and chemically characterized in earlier works. To supplement this, the present study provides comprehensive investigations regarding geotechnical properties of the three base regolith simulant systems: TUBS-M, TUBS-T, and TUBS-I. To evaluate the engineering and flow properties of these heterogeneous materials under various conditions, shear tests, particle size analyses, scanning electron microscope observations, and density investigations were conducted. It was shown that small grains <25 µm (lunar dust) are highly compressive and cohesive even at low external stress. They are particularly important as a large amount of fine dust is present in lunar regolith and simulants (x₅₀ = 76.7 to 96.0 µm). Further, ring shear and densification tests revealed correlations with damage mechanisms caused by local stress peaks for grains in the mm range. In addition, an explanation for the occurrence of considerable differences in the literature-based data for particle sizes was established by comparing various measurement procedures. The present study shows detailed geotechnical investigations of novel lunar regolith simulants, which can be used for the development of equipment for future lunar exploration missions and in situ resource utilization under realistic conditions. The results also provide evidence about possible correlations and causes of known soil-induced mission risks that so far have mostly been described phenomenologically.

The integration of electrically conductive functionalities into polymer components via additive manufacturing has gained increasing relevance across fields such as sensing, energy storage, and structural electronics. Achieving reliable performance in such applications requires a deeper understanding of how processing conditions affect the internal structure of conductive thermoplastic composites—particularly the orientation and distribution of anisotropic fillers. This study analyzes a PLA-based composite containing carbon nanotubes, carbon black, and graphite flakes to evaluate the influence of extrusion temperature on electrical resistivity and micromechanical properties. To complement scanning electron microscopy, a novel micromechanical mapping approach based on nanoindentation was applied, enabling spatially resolved analysis of local stiffness and hardness. Results show that increasing extrusion temperature improves filler dispersion and alignment, enhancing conductivity and mechanical homogeneity—up to a threshold of 210 °C. Even small temperature changes significantly affect particle orientation and distribution. Unlike global resistivity measurements, the combined use of nanoindentation and microscopic imaging reveals location-specific structural phenomena and filler behavior within the matrix. This newly established method provides high-resolution insight into internal composite architecture and offers a robust foundation for optimizing process-structure-property relationships in conductive polymer systems.