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A close encounter with a mysterious moon
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By NASA
5 min read
Preparations for Next Moonwalk Simulations Underway (and Underwater)
ICON’s next generation Vulcan construction system 3D printing a simulated Mars habitat for NASA’s Crew Health and Performance Exploration Analog (CHAPEA) missions.ICON One of the keys to a sustainable human presence on distant worlds is using local, or in-situ, resources which includes building materials for infrastructure such as habitats, radiation shielding, roads, and rocket launch and landing pads. NASA’s Space Technology Mission Directorate is leveraging its portfolio of programs and industry opportunities to develop in-situ, resource capabilities to help future Moon and Mars explorers build what they need. These technologies have made exciting progress for space applications as well as some impacts right here on Earth.
The Moon to Mars Planetary Autonomous Construction Technology (MMPACT) project, funded by NASA’s Game Changing Development program and managed at the agency’s Marshall Space Flight Center in Huntsville, Alabama, is exploring applications of large-scale, robotic 3D printing technology for construction on other planets. It sounds like the stuff of science fiction, but demonstrations using simulated lunar and Martian surface material, known as regolith, show the concept could become reality.
Lunar 3D printing prototype.Contour Crafting With its partners in industry and academic institutions, MMPACT is developing processing technologies for lunar and Martian construction materials. The binders for these materials, including water, could be extracted from the local regolith to reduce launch mass. The regolith itself is used as the aggregate, or granular material, for these concretes. NASA has evaluated these materials for decades, initially working with large-scale 3D printing pioneer, Dr. Behrokh Khoshnevis, a professor of civil, environmental and astronautical engineering at the University of Southern California in Los Angeles.
Khoshnevis developed techniques for large-scale extraterrestrial 3D printing under the NASA Innovative Advanced Concepts (NIAC) program. One of these processes is Contour Crafting, in which molten regolith and a binding agent are extruded from a nozzle to create infrastructure layer by layer. The process can be used to autonomously build monolithic structures like radiation shielding and rocket landing pads.
Continuing to work with the NIAC program, Khoshnevis also developed a 3D printing method called selective separation sintering, in which heat and pressure are applied to layers of powder to produce metallic, ceramic, or composite objects which could produce small-scale, more-precise hardware. This energy-efficient technique can be used on planetary surfaces as well as in microgravity environments like space stations to produce items including interlocking tiles and replacement parts.
While NASA’s efforts are ultimately aimed at developing technologies capable of building a sustainable human presence on other worlds, Khoshnevis is also setting his sights closer to home. He has created a company called Contour Crafting Corporation that will use 3D printing techniques advanced with NIAC funding to fabricate housing and other infrastructure here on Earth.
Another one of NASA’s partners in additive manufacturing, ICON of Austin, Texas, is doing the same, using 3D printing techniques for home construction on Earth, with robotics, software, and advanced material.
Construction is complete on a 3D-printed, 1,700-square-foot habitat that will simulate the challenges of a mission to Mars at NASA’s Johnson Space Center in Houston, Texas. The habitat will be home to four intrepid crew members for a one-year Crew Health and Performance Analog, or CHAPEA, mission. The first of three missions begins in the summer of 2023. The ICON company was among the participants in NASA’s 3D-Printed Habitat Challenge, which aimed to advance the technology needed to build housing in extraterrestrial environments. In 2021, ICON used its large-scale 3D printing system to build a 1,700 square-foot simulated Martian habitat that includes crew quarters, workstations and common lounge and food preparation areas. This habitat prototype, called Mars Dune Alpha, is part of NASA’s ongoing Crew Health and Performance Exploration Analog, a series of Mars surface mission simulations scheduled through 2026 at NASA’s Johnson Space Center in Houston.
With support from NASA’s Small Business Innovation Research program, ICON is also developing an Olympus construction system, which is designed to use local resources on the Moon and Mars as building materials.
The ICON company uses a robotic 3D printing technique called Laser Vitreous Multi-material Transformation, in which high-powered lasers melt local surface materials, or regolith, that then solidify to form strong, ceramic-like structures. Regolith can similarly be transformed to create infrastructure capable of withstanding environmental hazards like corrosive lunar dust, as well as radiation and temperature extremes.
The company is also characterizing the gravity-dependent properties of simulated lunar regolith in an experiment called Duneflow, which flew aboard a Blue Origin reusable suborbital rocket system through NASA’s Flight Opportunities program in February 2025. During that flight test, the vehicle simulated lunar gravity for approximately two minutes, enabling ICON and researchers from NASA to compare the behavior of simulant against real regolith obtained from the Moon during an Apollo mission.
Learn more: https://www.nasa.gov/space-technology-mission-directorate/
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Last Updated May 13, 2025 EditorLoura Hall Related Terms
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By NASA
Artemis II crew members, shown inside the Neil Armstrong Operations and Checkout Building at NASA’s Kennedy Space Center in Florida, stand in front of their Orion crew module on Aug. 8, 2023. Pictured from left are CSA (Canadian Space Agency) astronaut Jeremy Hansen, and NASA astronauts Victor Glover, Reid Wiseman, and Christina Koch.Credit: NASA/Kim Shiflett NASA will host a live Twitch event to highlight the ongoing Moon Mascot Challenge, which invites the public to design a zero gravity indicator for the agency’s Artemis II crewed test flight around the Moon. Viewers will have the opportunity to provide real-time input to an artist who will create an example of a zero gravity indicator during the livestream.
Zero gravity indicators are small, plush items carried aboard spacecraft to provide a visual indication of when the crew reaches space.
The event will begin at 3 p.m. EDT on Tuesday, May 13, on the agency’s official Twitch channel:
https://www.twitch.tv/nasa
The contest invites global creators of all ages to submit design ideas for a zero gravity indicator that will fly aboard the agency’s Artemis II test flight, the first crewed mission under NASA’s Artemis campaign.
Up to 25 finalists, including entries from a K-12 student division, will be selected. The Artemis II crew will choose one design that NASA’s Thermal Blanket Lab will fabricate to fly alongside the crew in the Orion spacecraft.
During this Twitch event, NASA experts will discuss the Moon Mascot Challenge while the artist incorporates live audience feedback into a sample design. Although the design example will not be eligible for the contest, it will demonstrate how challenge participants can develop their own zero gravity indicator designs. The example will be shared on the @NASAArtemis social media accounts following the Twitch event.
The Artemis II test flight will take NASA astronauts Reid Wiseman, Victor Glover, and Christina Koch, and CSA (Canadian Space Agency) astronaut Jeremy Hansen on a 10-day journey around the Moon and back. The mission is another step toward missions on the lunar surface to help the agency prepare for future human missions to Mars.
To learn more about NASA’s missions, visit:
https://www.nasa.gov
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Rachel Kraft
Headquarters, Washington
202-358-1600
rachel.h.kraft@nasa.gov
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Last Updated May 12, 2025 EditorJessica TaveauLocationNASA Headquarters Related Terms
Artemis 2 Earth's Moon Exploration Systems Development Mission Directorate Social Media View the full article
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