Synthetic space bricks from lunar and Martian regolith via sintering

Abstract

The prospect of establishing extra-terrestrial habitats using in situ resource utilization (ISRU) constitutes a long-term goal of multiple space agencies around the world. In this work, we investigate furnace sintering as a potential route for making building blocks—termed synthetic space bricks—using in situ regolith material. By systematically evaluating sintering parameters using a numerical lattice model, coupled with experimental observations and post-sintering characterization, we propose a process protocol for two lunar simulants (lunar highland simulant (LHS-1) and lunar mare dust simulant (LMS-1)) and one Martian simulant (mars global simulant, MGS-1). The resulting bricks demonstrate compressive strengths of up to 45 MPa under uniaxial loading, depending on the simulant used. These strengths are much greater than those typically mandated for structural applications under reduced gravity. Taking recourse to classical ceramic sintering studies, we infer particle-level sintering mechanisms indirectly by measuring temporal evolution exponents of sample dimensions. For all three simulants, volume diffusion appears to be the primary mechanism for particle coalescence. Our results clearly make a strong case for the use of sintering as a potentially scalable method for consolidating regolith into brick-like structures for construction and load-bearing applications in extra-terrestrial settings.