3D printing will help space pioneers make homes, tools and other stuff they need to colonize the Moon and Mars

Sven Bilén, Penn State

Throughout history, when pioneers set out across uncharted territory to settle in distant lands, they carried with them only the essentials: tools, seeds and clothing. Anything else would have to come from their new environment.

So they built shelter from local timber, rocks and sod; foraged for food and cultivated the soil beneath their feet; and fabricated tools from whatever they could scrounge up. It was difficult, but ultimately the successful ones made everything they needed to survive.

Something similar will take place when humanity leaves Earth for destinations such as the Moon and Mars – although astronauts will face even greater challenges than, for example, the Vikings did when they reached Greenland and Newfoundland. Not only will the astronauts have limited supplies and the need to live off the land; they won’t even be able to breathe the air.

Instead of axes and plows, however, today’s space pioneers will bring 3D printers. As an engineer and professor who is developing technologies to extend the human presence beyond Earth, I focus my work and research on these remarkable machines.

3D printers will make the tools, structures and habitats space pioneers need to survive in a hostile alien environment. They will enable long-term human presence on the Moon and Mars.

From hammers to habitats

On Earth, 3D printing can fabricate, layer by layer, thousands of things, from replacement hips to hammers to homes. These devices take raw materials, such as plastic, concrete or metal, and deposit it on a computerized programmed path to build a part. It’s often called “additive manufacturing,” because you keep adding material to make the part, rather than removing material, as is done in conventional machining.

Already, 3D printing in space is underway. On the International Space Station, astronauts use 3D printers to make tools and spare parts, such as ratchet wrenches, clamps and brackets. Depending on the part, printing time can take from around 30 minutes to several hours.

For now, the print materials are mostly hauled up from Earth. But NASA has also begun recycling some of those materials, such as waste plastic, to make new parts with the Refabricator, an advanced 3D printer installed in 2019.

Advertisement

Manufacturing in space

You may be wondering why space explorers can’t simply bring everything they need with them. After all, that’s how the International Space Station was built decades ago – by hauling tons of prefabricated components from Earth.

But that’s impractical for building habitats on other worlds. Launching materials into space is incredibly expensive. Right now, every pound launched aboard a rocket just to get to low Earth orbit costs thousands of dollars. To get materials to the Moon, NASA estimates the initial cost at around US$500,000 per pound.

Still, manufacturing things in space is a challenge. In the microgravity of space, or the reduced gravity of the Moon or Mars, materials behave differently than they do on Earth. Decrease or remove gravity, and materials cool and recrystallize differently. The Moon has one-sixth the gravity of Earth; Mars, about two-fifths. Engineers and scientists are working now to adapt 3D printers to function in these conditions.

Using otherworldly soil

On alien worlds, rather than plastic or metal, 3D printers will use the natural resources found in these environments. But finding the right raw materials is not easy. Habitats on the Moon and Mars must protect astronauts from the lack of air, extreme temperatures, micrometeorite impacts and radiation.

Regolith, the fine, dusty, sandlike particles that cover both the lunar and Martian surfaces, could be a primary ingredient to make these dwellings. Think of the regolith on both worlds as alien dirt – unlike Earth soil, it contains few nutrients, and as far as we know, no living organisms. But it might be a good raw material for 3D printing.

My colleagues began researching this possibility by first examining how regular cement behaves in space. I am now joining them to develop techniques for turning regolith into a printable material and to eventually test these on the Moon.

But obtaining otherworldly regolith is a problem. The regolith samples returned from the Moon during the Apollo missions in the 1960s and 70s are precious, difficult if not impossible to access for research purposes. So scientists are using regolith simulants to test ideas. Actual regolith may react quite differently than our simulants. We just don’t know.

What’s more, the regolith on the Moon is very different from what’s found on Mars. Martian regolith contains iron oxide –that’s what gives it a reddish color – but Moon regolith is mostly silicates; it’s much finer and more angular. Researchers will need to learn how to use both types in a 3D printer. https://www.youtube.com/embed/J1TWlNWHrsw?wmode=transparent&start=0 See models of otherworldly habitats.

Advertisement

Applications on Earth

NASA’s Moon-to-Mars Planetary Autonomous Construction Technology program, also known as MMPACT, is advancing the technology needed to print these habitats on alien worlds.

Among the approaches scientists are now exploring: a regolith-based concrete made in part from surface ice; melting the regolith at high temperatures, and then using molds to form it while it’s a liquid; and sintering, which means heating the regolith with concentrated sunlight, lasers or microwaves to fuse particles together without the need for binders.

Along those lines, my colleagues and I developed a Martian concrete we call MarsCrete, a material we used to 3D-print a small test structure for NASA in 2017.

Then, in May 2019, using another type of special concrete, we 3D-printed a one-third scale prototype Mars habitat that could support everything astronauts would need for long-term survival, including living, sleeping, research and food-production modules.

That prototype showcased the potential, and the challenges, of building housing on the red planet. But many of these technologies will benefit people on Earth too.

In the same way astronauts will make sustainable products from natural resources, homebuilders could make concretes from binders and aggregates found locally, and maybe even from recycled construction debris. Engineers are already adapting the techniques that could print Martian habitats to address housing shortages here at home. Indeed, 3D-printed homes are already on the market.

Meanwhile, the move continues toward establishing a human presence outside the Earth. Artemis III, now scheduled for liftoff in 2027, will be the first human Moon landing since 1972. A NASA trip to Mars could happen as early as 2035.

Advertisement

But wherever people go, and whenever they get there, I’m certain that 3D printers will be one of the primary tools to let human beings live off alien land.

Sven Bilén, Professor of Engineering Design, Electrical Engineering and Aerospace Engineering, Penn State

This article is republished from The Conversation under a Creative Commons license. Read the original article.

Blue Origin has once again solidified its position as a leader in the space launch industry with the recent award of a National Security Space Launch (NSSL) Phase 3 Lane 2 contract. This significant contract will designate New Glenn as a heavy-lift provider for some of the nation’s most crucial missions. As the company expresses pride in supporting the Department of Defense and the National Reconnaissance Office, this achievement highlights a pivotal movement towards enhancing the diversity of launch providers, ultimately ensuring sustained competition for secure access to space.

In response to the announcement, Jarrett Jones, Senior Vice President of New Glenn, remarked, “It’s an honor and huge responsibility to team with the U.S. Government to launch our nation’s most important assets. Through this partnership, we’re looking forward to delivering on a number of critical national security priorities.” This sentiment underscores the serious nature of the tasks ahead, emphasizing the commitment to safeguarding national interests through reliable space capabilities.

As part of this contract, New Glenn will undertake missions that involve challenging orbits, necessitating advanced performance launch systems and comprehensive mission assurance. The inclusion of the Space Systems Command (SSC) certification further validates New Glenn’s capacity to meet the rigorous demands of national security missions. The payloads delivered under this contract will be instrumental in promoting the United States’ strategic advantage in space.

Remarkably, this contract represents the third national security launch-related award Blue Origin has secured within the past year. Following a contract win in June 2024 for NSSL Phase 3 Lane 1 missions, and an additional award in July 2024 that allows New Glenn to compete for missions in the Orbital Services Program (OSP)-4, Blue Origin is positioning itself as a steadfast player in the evolving landscape of national security space operations.

The trajectory of New Glenn’s contracts reflects the company’s growing involvement in this critical sector, as evidenced by its successful NG-1 launch, which marked its first NSSL certification flight in January. Looking ahead, expectations are set high with the upcoming NG-2 launch planned for late spring, which aims to further validate the capabilities and reliability of New Glenn.

With this latest award, Blue Origin continues to demonstrate its commitment to enhancing national security through innovative launch solutions. As we witness the expansion of opportunities in the space sector, Blue Origin remains a key partner in ensuring that the United States can effectively meet its defense and reconnaissance objectives, all while maintaining a competitive edge in the global arena.

For further details on this exciting announcement, please visit [Blue Origin’s official site](insert link here).

Stay tuned for more updates as we continue to follow the journey of New Glenn and its integral role in national security!

Advertisement

Related link:

https://www.blueorigin.com/news/new-glenn-awarded-critical-national-security-space-launch-contract

The science section of our news blog STM Daily News provides readers with captivating and up-to-date information on the latest scientific discoveries, breakthroughs, and innovations across various fields. We offer engaging and accessible content, ensuring that readers with different levels of scientific knowledge can stay informed. Whether it’s exploring advancements in medicine, astronomy, technology, or environmental sciences, our science section strives to shed light on the intriguing world of scientific exploration and its profound impact on our daily lives. From thought-provoking articles to informative interviews with experts in the field, STM Daily News Science offers a harmonious blend of factual reporting, analysis, and exploration, making it a go-to source for science enthusiasts and curious minds. https://stmdailynews.com/category/science/

NASA is set to offer live coverage of the much-anticipated return of its SpaceX Crew-9 mission from the International Space Station (ISS). The event will commence with preparations for the Dragon spacecraft’s hatch closure at 10:45 p.m. EDT on Monday, March 17.

In a proactive move, NASA and SpaceX convened on Sunday to evaluate the weather and splashdown conditions off Florida’s coast in preparation for the Crew-9 mission return. Thanks to favorable weather forecasts for Tuesday evening, March 18, mission managers are targeting an earlier return opportunity. This adjustment serves to allow the onboard crew ample time to complete their handover duties while also providing operational flexibility in anticipation of less favorable weather later in the week.

The Crew-9 mission features NASA astronauts Nick Hague, Suni Williams, and Butch Wilmore, along with Roscosmos cosmonaut Aleksandr Gorbunov. These skilled astronauts have been conducting a long-duration science expedition aboard the ISS and will bring back critical time-sensitive research to Earth.

As the launch nears, mission managers will continue to monitor weather conditions, which will play a pivotal role in the undocking process. Factors such as spacecraft readiness, recovery team preparedness, and sea states will all influence the timing and location of the splashdown. NASA and SpaceX will finalize and communicate the specific splashdown site as the Crew-9 return approaches.

For those interested in following along, you can watch the Crew-9 return activities live on NASA+. Additional viewing options, including various social media platforms, are also available. Schedule information can be found at NASA Live.

Here’s a timeline of the upcoming live coverage (all times EDT and subject to change):

Monday, March 17

• 10:45 p.m. – Hatch closing coverage begins on NASA+

Tuesday, March 18

• 12:45 a.m. – Undocking coverage begins on NASA+
• 1:05 a.m. – Undocking

Following the undocking coverage, there will be an audio-only feed. Assuming favorable weather conditions at the splashdown sites, continuous coverage will resume on NASA+ before the deorbit burn.

• 4:45 p.m. – Return coverage begins on NASA+
• 5:11 p.m. – Deorbit burn (approximate time)
• 5:57 p.m. – Splashdown (approximate time)

Following the splashdown, there will be a Return-to-Earth media conference at 7:30 p.m. on NASA+, featuring key participants, including:

• Joel Montalbano, Deputy Associate Administrator, NASA’s Space Operations Mission Directorate
• Steve Stich, Manager, NASA’s Commercial Crew Program
• Jeff Arend, Manager for Systems Engineering and Integration, NASA’s International Space Station Office
• Sarah Walker, Director, Dragon Mission Management, SpaceX

Mark your calendars and prepare to witness this exciting milestone in space exploration as NASA’s Crew-9 mission returns home!

Find full mission coverage, NASA’s commercial crew blog, and more information about the Crew-9 mission at:

Advertisement

https://www.nasa.gov/commercialcrew

The science section of our news blog STM Daily News provides readers with captivating and up-to-date information on the latest scientific discoveries, breakthroughs, and innovations across various fields. We offer engaging and accessible content, ensuring that readers with different levels of scientific knowledge can stay informed. Whether it’s exploring advancements in medicine, astronomy, technology, or environmental sciences, our science section strives to shed light on the intriguing world of scientific exploration and its profound impact on our daily lives. From thought-provoking articles to informative interviews with experts in the field, STM Daily News Science offers a harmonious blend of factual reporting, analysis, and exploration, making it a go-to source for science enthusiasts and curious minds alike. https://stmdailynews.com/category/science/