Author(s): Kalp Agarwal and Archit Dhingra

Abstract: The increasing interest in establishing permanent human settlements on the Moon and Mars has accelerated the development of habitat construction technologies based on In-Situ Resource Utilisation (ISRU). Among the available approaches, regolith-based composite materials have emerged as promising candidates due to their ability to utilise local resources, reduce transportation costs, and enhance mission sustainability. However, habitat hulls must provide high mechanical strength, thermal stability, radiation shielding, and long-term durability under harsh extraterrestrial environments. This review presents a comprehensive analysis of the thermo-mechanical performance of regolith-based composite hull structures, covering engineering requirements, material development, thermo-mechanical behaviour, additive manufacturing, comparative mechanical performance, research challenges, and future directions. Comparative analysis shows that Regolith Resin Composites (RRC) exhibit the highest compressive strength (107.7 Megapascals (MPa)). In contrast, Multi-Walled Carbon Nanotubes (MWCNT), Polyether Ether Ketone (PEEK), and fibre-reinforced composites offer improved thermal stability and lightweight performance for ISRU-based habitat construction. The review concludes that integrating advanced composite materials with autonomous additive manufacturing, artificial intelligence-assisted material optimisation, and next-generation ISRU technologies would enhance the safety, sustainability, and reliability of future lunar and Martian habitats.

DOI: https://www.doi.org/10.22271/27078043.2026.v7.i2b.141

Pages: 96-103 | Views: 96 | Downloads: 55

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