Abstract
•Reviewed current efforts on developing an extra-terrestrial construction process.•The review consists of three categories: materials, fabrication and process.•Discussed the major concerns and challenges for the above efforts.•The above efforts would support permanent settlement of other planetary bodies.•A logical pathway is to develop an appropriate AM-based printing system.
Government space agencies, including NASA and ESA, are conducting preliminary studies on building alternative space-habitat systems for deep-space exploration. Such studies include development of advanced technologies for planetary surface exploration, including an in-depth understanding of the use of local resources. Currently, NASA plans to land humans on Mars in the 2030s. Similarly, other space agencies from Europe (ESA), Canada (CSA), Russia (Roscosmos), India (ISRO), Japan (JAXA) and China (CNSA) have already initiated or announced their plans for launching a series of lunar missions over the next decade, ranging from orbiters, landers and rovers for extended stays on the lunar surface. As the Space Odyssey is one of humanity’s oldest dreams, there has been a series of research works for establishing temporary or permanent settlement on other planetary bodies, including the Moon and Mars. This paper reviews current projects developing extra-terrestrial construction, broadly categorised as: (i) ISRU-based construction materials; (ii) fabrication methods; and (iii) construction processes. It also discusses four categories of challenges to developing an appropriate construction process: (i) lunar simulants; (ii) material fabrication and curing; (iii) microwave-sintering based fabrication; and (iv) fully autonomous and scaled-up construction processes.