Due to payload weight limitations and human vulnerability to harsh space conditions, it is preferable that the potential landing location for humans has an already constructed habitat preferably made from in situ materials. Therefore, the prospect of utilizing a readily available Martian material, such as regolith, in an easily programmable manufacturing method, such as 3D printing, is very lucrative. The goal of this research is to explore a mixture containing Martian regolith for the purposes of 3D printing in unfavorable conditions. A binder consisting of water and sodium silicate is used. Martian conditions are less favorable for the curing of such a mixture because of low temperature and pressure on the surface of the planet. In order to evaluate mechanical properties of the mixture, molding and 3D printing were conducted at various curing conditions and the mechanical and physical characteristics were compared. Due to the combination of low reaction speed at low temperature (2 °C) and rapid water evaporation at low pressure (0.1–0.01 bar), curing of the specimens in Martian conditions yielded unsatisfactory results. The reaction medium (water) evaporated before the curing reaction could progress enough to form a proper geopolymer. The specimens cured at high temperatures (60 °C) showed satisfactory results, with flexural strength up to 9 MPa when cured at a temperature of 60 °C and pressure of 1 bar. The specimens manufactured by 3D printing showed ultimate flexural strength that was 20% lower than that of equivalent molded specimens. Exploring potential mixture modifications and performing improved tests using the basis laid in this research can lead to an effective and realistic way of utilizing Martian regolith for unmanned 3D-printing purposes with minimal investment.

Heavily resource-reliant transportation and harsh living conditions, where humans cannot survive without a proper habitat, have prevented humans from establishing colonies on the Moon and Mars. Due to the absence of an atmosphere, potential habitats on the Moon or Mars require thick and strong structures that can withstand artificially produced internal pressure, potential meteoroid strikes, and the majority of incoming radiation. One promising way to overcome the noted challenges is the use of additive manufacturing (AM), also known as 3D printing. It allows producing structures from abundant materials with minimal material manipulation as compared to traditional constructing techniques. In addition to constructing the habitat itself, 3D printing can be utilized for manufacturing various tools that are useful for humans. Recycling used-up tools to compensate for damaged or unfunctional devices is also possible by melting down a tool back into raw material. While space 3D printing sounds good on paper, there are various challenges that still have to be considered for printing-assisted space missions. The conditions in space are drastically different from those on Earth. This includes factors such as the absence of gravity, infinitesimal pressure, and rapid changes in temperature. In this paper, a literature study on the prospects of additive manufacturing in space is presented. There are a variety of 3D printing techniques available, which differ according to the materials that can be utilized, the possible shapes of the final products, and the way solidification of the material occurs. In order to send humans to other celestial bodies, it is important to account for their needs and be able to fulfill them. An overview of requirements for potential space habitats and the challenges that arise when considering the use of additive manufacturing in space are also presented. Finally, current research progress on 3D printing Lunar and Martian habitats and smaller items is reviewed.