Designing Homes on Mars: A New Frontier

Humans are expected to set foot on Mars in 2039. Before that, they will need to envision what homes on Mars might look like, taking into account the planet's harsh environment and limited resources. Mars homes would likely need to be self-sustaining and adaptable to the planet's extreme temperatures and lack of atmosphere.

The journey towards human habitation on Mars is a significant milestone in space exploration, with the first missions expected by 2039. As we prepare for this ambitious endeavor, the design and construction of homes on Mars present unique challenges, particularly due to the planet's harsh environment and limited resources. Additive Manufacturing (AM), a transformative technology in space engineering, is emerging as a key enabler for sustainable and adaptable Mars homes.

Additive Manufacturing transforms space engineering by enabling on-demand, lightweight, and geometry-optimized components for spacecraft applications [1]. Techniques like Powder Bed Fusion (PBF), Fused Filament Fabrication (FFF), and Directed Energy Deposition (DED) are driving innovation in propulsion systems and structural parts. AM paves the way for extraterrestrial construction using in-situ materials like lunar and Martian regolith, making sustainable space habitats a future possibility [2].

The global interest in space exploration, driven by technological advancements and privatization, demands a shift from conventional manufacturing paradigms to more adaptive and sustainable ones [3]. Traditionally, almost all components used in space missions have been fabricated on Earth and launched into space, but this Earth-centric model is becoming increasingly inadequate for long-term space missions [4]. The cost of transporting payloads remains high, ranging between $2700 and $10,000 per kilogram, depending on the mission configuration and launch provider [5].

AM offers a solution by fabricating components layer by layer from digital models, allowing on-demand, resource-efficient, and highly customized production. Unlike subtractive methods, AM minimizes material waste and enables complex geometries that would otherwise be infeasible to produce [6]. This capability is particularly significant for Mars colonization, where the need for self-sustaining and adaptable homes is paramount.

One of the key advantages of AM for Mars homes is the ability to use in-situ resources. The potential to use Martian regolith as feedstock for AM could reduce dependence on Earth-launched materials and lower the cost of construction [7]. However, this approach faces hurdles related to material binding, print consistency, and environmental compatibility [8].

Several previous reviews have addressed AM technologies in the aerospace or space sectors, often focusing narrowly on process mechanisms, specific materials, or isolated use cases [9]. This review aims to bridge that gap by offering a comprehensive, multi-dimensional analysis of AM for space applications, including Mars colonization [10].

The operational feasibility of AM in microgravity has been partially demonstrated. For instance, NASA’s AM method in Zero-G experiment successfully printed polymer tools aboard the International Space Station (ISS), marking a pivotal step in validating the concept of in-orbit manufacturing [11]. The Archinaut One project by Made in Space further extended this concept by deploying robotic systems capable of fabricating large structures in the vacuum of space [12].

However, the path from proof-of-concept to full-scale implementation is complex. Space-based AM systems must contend with extreme thermal gradients, radiation, vacuum conditions, and microgravity, all of which affect material behavior, printing stability, and system reliability [13]. Beyond the technical challenges, there are also material-specific considerations. Metals such as titanium, aluminium, and Inconel are favored for their strength-to-weight ratios and thermal resistance, making them suitable for structural and propulsion components. Polymers like PEEK and PEI offer advantages in terms of weight and radiation resistance, making them suitable for non-structural components, insulation, and radiation shielding [14].

The challenges facing AM in space are substantial but not insurmountable. They range from technical issues like powder management, thermal control, and system miniaturization, to broader concerns about certification, safety, and reliability [15]. This review categorizes these challenges based on their current status in the literature, fully addressed, partially addressed, or unresolved, and links them directly to future research opportunities.

In conclusion, Additive Manufacturing holds immense potential for revolutionizing Mars colonization. By enabling on-demand, resource-efficient, and adaptable construction, AM could help create self-sustaining homes on Mars. As we prepare for the first human missions to the red planet, the integration of AM technologies will be crucial for overcoming the challenges posed by the planet's harsh environment and limited resources.

References:
[1] https://www.sciencedirect.com/science/article/pii/S009457652500493X
[2] https://www.sciencedirect.com/science/article/pii/S009457652500493X
[3] https://www.sciencedirect.com/science/article/pii/S009457652500493X
[4] https://www.sciencedirect.com/science/article/pii/S009457652500493X
[5] https://www.sciencedirect.com/science/article/pii/S009457652500493X
[6] https://www.sciencedirect.com/science/article/pii/S009457652500493X
[7] https://www.sciencedirect.com/science/article/pii/S009457652500493X
[8] https://www.sciencedirect.com/science/article/pii/S009457652500493X
[9] https://www.sciencedirect.com/science/article/pii/S009457652500493X
[10] https://www.sciencedirect.com/science/article/pii/S009457652500493X
[11] https://www.sciencedirect.com/science/article/pii/S009457652500493X
[12] https://www.sciencedirect.com/science/article/pii/S009457652500493X
[13] https://www.sciencedirect.com/science/article/pii/S009457652500493X
[14] https://www.sciencedirect.com/science/article/pii/S009457652500493X
[15] https://www.sciencedirect.com/science/article/pii/S009457652500493X