For economic, scientific and survival reasons, colonisation of other planets is proposed. Mars is the most suitable place to start. To start an early Martian colony, viable In-Situ Resource Utilisation (ISRU) methods of low energy consumption are required to manufacture strong bulk construction materials. Most other studies have used infeasible materials or processes to investigate the possibility of manufacturing construction materials on Mars. This study investigated answers to this problem and assessed the feasibility thereof under strict requirements.

A literature study has specified Martian regolith as the optimal raw resource. The use of water was not feasible. Simulants MGS-1 and JEZ-1 were used as materials analogous to Martian regolith. Spark Plasma Sintering (SPS) has been chosen as the optimal production method considering Martian regolith and the environment. An experimental study has verified the feasibility of the proposed material combined with the proposed method. Standard compressive tests, CT, SEM, SEM-EDS, DSC-TGA, Taguchi Design, MSEL and SPS, accompanied by standard measurements, yielded the following information: uniaxial compressive strength, density (distribution), macro porosity, microstructure, elemental composition, compaction, and energy requirement. Both simulant types were subject to three modifications: particle size, particle size reduction method and drying. Four SPS parameters have been analysed: temperature, duration, applied coating and applied pressure.

The minimum required compressive strength of 1.9 MPa was readily achieved. A maximum compressive strength of 137 MPa was found with an average of 48.50 MPa. Combined with the possible shape geometries of SPS, the manufactured material is expected to be structurally applicable. The measured theoretical energy requirement was 17.07 GJ/m³. The applied energy use was 2.72 TJ/m³. A reference dome requires a feasible theoretical 89.5 kW or infeasible applied 14.3 MW for one year. The latter value was elevated due to experimental factors. The actual energy requirement of a Martian mission is expected to be closer to the theoretical energy requirement due to efficiency improvements. Water vapour was produced during sintering. This is a vital benefit to a Martian colony. To conclude, ISRU bulk construction material manufacturing on Mars, for early colony development, is possible with regolith simulant and SPS.