Most proposals for construction of settlements on Moon and Mars are based on
transporting structural elements from Earth and assembling them at the destination. A far less
expensive and potentially practical approach is using Contour Crafting, a large-scale AM
process, in conjunction with in-situ materials. Our trials with sulfur based concrete and sintered
lunar regolith simulant made by NASA show strong promise. Our project ultimately aims at
demonstration of lunar outpost infrastructure construction involving landing pads, blast walls,
roads, shade walls and protective hangars. This paper reports on our very early efforts in the first
stage of the project.Mechanical Engineerin
