Design, Analysis, and Prototype of The Mars Sintering System (MRSS)

Abstract

As human exploration of Mars advances, autonomous in-situ construction systems are required to enable sustainable surface infrastructure. This study presents the design, prototyping, and experimental evaluation of a Mars Sintering System (MRSS) capable of converting Martian regolith simulant into structurally stable bricks for robotic assembly. Developed in collaboration with NASA’s Jet Propulsion Laboratory, the system targets autonomous operation under Martian constraints including low atmospheric pressure, reduced convective heat transfer, limited power availability, and high dust exposure. Multiple sintering approaches,furnace, microwave, laser, and solar-assisted heating, were experimentally evaluated using JSC Mars-1A simulant. Results indicate that effective densification occurs above 1050 °C, with dwell time, charge mass, and container geometry significantly influencing consolidation. Furnace sintering provided the most consistent bulk densification, while microwave sintering achieved comparable cohesion with lower power consumption and cycle times of 15–25 min per brick. Laser-based heating enabled localized melting but required power levels impractical for near-term deployment. Preliminary mechanical testing confirmed that optimized samples exhibit sufficient compressive integrity for non-load-bearing applications such as shielding and structural infill. The MRSS integrates thermal processing, automated handling, and low-power operation within a prototype system constrained by budget and energy limits. These findings demonstrate the feasibility of sintering-based regolith processing for autonomous planetary construction and provide design guidance for future Mars surface manufacturing systems.