Off-Earth infrastructure assembly: A conceptual method for scaffoldless and mortarless component-based structures in static equilibrium

Extra-terrestrial infrastructure design and architecture are experiencing a resurgence due to the prospect of permanent human presence on celestial bodies such as our moon and Mars. There, the conditions and constraints within which structural design and assembly should be developed are extreme – for example, scarcity of processed structural material, labour, machinery and imports from Earth. Consequently, the guiding design principles for building off-Earth should include efficient In-Situ Resource Utilisation (ISRU) and reusability. Significantly, these aspects have striking similarities to some characteristics of our vernacular construction history on Earth, such as inherent material efficiency and use of local materials. The majority of contemporary proposals for off-Earth design concern 3D-printed monolithic structures which are not reusable nor reconfigurable. As a result, there is scope for developing component-based, recyclable infrastructure which is based on efficient ISRU. In this research paper, we propose a two-fold assembly and structural design methodology which synthesises three-dimensional geometries in static equilibrium and vernacular construction techniques for deriving scaffoldless, component-based structures. This framework is underpinned by the development of a bespoke mechanically interlocking system which enables mortarless construction. This minimises the need for importing material binders and maximises the reconfigurability and reusability of off-Earth infrastructure.