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.

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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.

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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.

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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.

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For 120 years, BRACH’S^® Candy has been loved for trusted, quality sugar confections that are known for making moments sweeter. Today, BRACH’S is America’s Easter jelly bean leader and the #1 seasonal sugar candy brand⁵. The portfolio leads with iconic product forms, including Conversation Hearts, Easter Jelly Beans, Candy Corn and Candy Canes. Each of BRACH’S product offerings come in a variety of shapes, textures, and flavors made for all seasonal festivities. BRACH’S inspires connection and celebration with its classic candy treats and innovations, perfect for snacking, decorating, baking, gifting, and so much more. To learn more about BRACH’S, visit brachs.com, or follow along on TikTok, Facebook, Instagram, and Pinterest.

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SOURCE: 

¹ #1 Seasonal Easter Jelly Bean Brand – Circana Market Advantage Total US MULO+C: Easter Season 8 Weeks WE 3.31.24

² Survey conducted by Zappi on behalf of BRACH’S^® in February 2025 with a sample of 2,000 U.S. adults age 18+ who celebrate Easter. The margin of error at this sample size is +/- 2.5% at the 95% confidence level. Use of words “Americans” refers to the 90% of Americans screened into this survey for celebrating Easter (nationally representative sample of n=2,000).

³ U.S. Jelly Bean Sales/Top 10 Markets – IRI Data Ending 3.31.24

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Adam Simpson, University of South Australia

In early 2021, after a decade of political and economic reforms, Myanmar looked like it was finally beginning to shake off the hangover of decades of military rule. Foreign investment was growing, and standards of living were gradually improving.

In February that year, however, the military again grabbed power after ousting Aung San Suu Kyi’s democratically elected government in a coup. This sent the country spiralling towards civil war and social and economic collapse.

In the latest addition to the daily misery of Myanmar’s long-suffering people, a huge 7.7-magnitude earthquake hit the centre of the country on Friday. Its epicentre was just outside Mandalay, the county’s second-largest city.

The Thai capital of Bangkok, more than 1,000 kilometres from the epicentre, experienced extensive damage too. Video images showed a collapsing building under construction and sloshing rooftop infinity pools causing waterfalls down high-rise condominiums.

Information on the extent of the damage in Myanmar was slower to emerge, given the junta has largely banned social media and communications apps, such as Facebook, Instagram, WhatsApp, Signal and X.

The death toll has now passed 1,000 at the time of writing. US Geological Survey modelling, however, suggests there could be more than 10,000 deaths and economic losses potentially exceeding the country’s gross domestic product (GDP).

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Unusually for the isolationist military juntas of Myanmar, its leader, Min Aung Hlaing, immediately issued a call for international assistance.

The junta, however, has full control of as little as 21% of the country in the ongoing civil war, with the rest contested or controlled by ethnic armed groups and resistance fighters. This indicates some hard-hit areas of the country may be inaccessible to international aid.

Compounding these difficulties, the Trump administration has decimated the US Agency for International Development (USAID) activities in the country. This will make it far more challenging to determine the areas most in need and distribute any aid on the ground.

Natural disasters in Myanmar

Along with its history of brutal and authoritarian military rule since gaining independence in 1948, Myanmar is also regularly afflicted by natural disasters.

At least 430 people are believed to have died in floods last September due to the remnants of Typhoon Yagi. In 2023, Cyclone Mocha reportedly killed about 460 of the Rohingya ethnic minority, who are largely confined to government camps in Rakhine state in inhuman conditions.

The worst natural disaster in living memory, however, was Cyclone Nargis in 2008, which left at least 140,000 dead. On that occasion, the military junta resisted international assistance, likely resulting in many unnecessary deaths.

At that time, there was no independent media in Myanmar and it was almost impossible to find out what was actually happening on the ground.

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Fortunately, the proliferation of mobile phones in the last decade has allowed information to spread much more widely, even with the junta’s internet blocks and other methods of censorship currently in place.

When Cyclone Nargis occurred – the year after the iPhone was launched – only around 1% of the Myanmar’s population had mobile phones. By the time of the coup in 2021, Myanmar had a smartphone penetration rate of 114%. (This means the country has more smartphones than people.)

Foreign assistance has been compromised

While Min Aung Hlaing has gone farther than his predecessor in 2008 in asking for international help, US President Donald Trump’s actions have ensured that any aid will be far less effective than it would have been two months ago.

On Friday, the same day the earthquake hit, the Trump administration told Congress it would cut nearly all remaining jobs at USAID and shut the agency, closing all USAID missions worldwide.

Jeremy Konyndyk, the president of Refugees International and a former USAID official, called the move “a total abdication of decades of US leadership in the world”. He argued the firings would cut “the last remnants of the team that would have mobilised a USAID disaster response” to the earthquake.

In 2024, USAID spent US$240 million (A$380 million) in Myanmar, around one-third of all multilateral humanitarian assistance to the country.

However, since Trump’s inauguration in January, the number of USAID programs in Myanmar has shrunk from 18 to just three. Several NGOs and at least seven US-funded hospitals operating along Myanmar’s border with Thailand have been shut down.

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Myanmar’s exiled independent media outlets, which shine a light on the military’s atrocities, have also seen their funding slashed by the Trump administration’s USAID cuts.

What happens now?

The day before the earthquake, Min Aung Hlaing addressed troops at the 80th anniversary of Armed Forces Day Parade. He announced national elections would go ahead in December – a vote that human rights groups are already calling a “sham”.

There is no conceivable way elections of any integrity can be held in the country under military rule or while the civil war continues to rage.

Military-backed parties have been overwhelmingly rejected by Myanmar’s electorate in every remotely free or fair election over the last four decades. This includes the most recent elections held in 2020, won by the National League of Democracy (NLD), led by Aung San Suu Kyi.

While the world should welcome – and urgently respond to – Min Aung Hlaing’s invitation for international assistance, this doesn’t mean the past is forgotten. Thousands of innocent lives have been lost as a result of the military’s unnecessary and destructive 2021 coup.

If the NLD had remained in government, the country would be infinitely more prepared to deal with consequences of this earthquake. Once again, the military’s brutal rule – and Trump’s draconian aid cuts – will no doubt cause more unnecessary suffering and deaths.

Adam Simpson, Senior Lecturer, International Studies, University of South Australia

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