On the Structural Design and Additive Construction Process of Martian Habitat Units Using In-Situ Resources on Mars

Taking the leap to the secondary and tertiary generations of the missions to Mars, a comprehensive outline was presented for a cluster of Martian Habitat Units (MHUs) designed for long-term settlements of research crew in Melas Chasma, Valles Marineris, Mars. Unlike initial exploration missions, where primary survival is ensured through basic engineering solutions, this concept targets later-stage missions focused on long-term human presence. Accordingly, the MHUs are designed not only for functionality but also to support the social and cultural well-being of scientific personnel, resulting in larger and more complex structures than those typically proposed for early-stage landings. To address the construction and structural integrity of the MHUs, the current work presents a comprehensive analysis of the feasibility of semi-3D-printed structural systems using in situ material to minimize the cost and engineering effort of logistics and construction of the units. Regolith-based additive manufacturing was utilized as the primary material, and the response of the structure, not only to the gravitational loads but also to those applied from the exterior flow field and wind pressure distributions, was simulated, as well as the considerations regarding the contribution of the extreme interior/exterior pressure differences. The full analyses and structural results are presented and discussed in this manuscript, as well as insights on manufacturing and its feasibility on Mars. The analyses demonstrate the feasibility of constructing the complex architectural requirements of the MHUs and their cost-effectiveness through the use of in situ resources. The manuscript presents an iterative structural optimization process, with results detailed at each step. Structural elements were modeled using FEM-based analysis in Karamba-3D to minimize near-yielding effects such as buckling and excessive displacements. The final structural system was integrated with the architectural design to preserve the intended spatial and functional qualities.