Cold sintering for in-space materials fabrication: a science, engineering, and future directions

Abstract The Cold Sintering Process (CSP) has recently emerged as a transformative approach for densifying ceramics and composites at temperatures below 300 °C using pressure-assisted dissolution–precipitation. This low-energy route is particularly compelling for in-situ resource utilization (ISRU) in extraterrestrial environments, where transporting construction materials from Earth is impractical. This review critically examines the potential of CSP for fabricating structural and functional materials in space, spanning lunar, Martian, orbital, deep-space, and asteroid contexts. We analyze the fundamental mechanisms of CSP, recent experimental demonstrations on lunar and Martian regolith simulants, and its integration with additive manufacturing, robotics, and artificial intelligence. Case studies highlight the production of high-strength regolith bricks (> 200 MPa) at low energy cost, showing CSP’s feasibility for building load-bearing structures on the Moon and Mars. We further explore frontier applications, including radiation shielding, multifunctional composites, and autonomous construction systems. Challenges such as solvent sourcing, high-pressure requirements, and environmental constraints are discussed in detail. Finally, we outline research directions toward scaling CSP for large habitats, integrating it with space architecture, and deploying it as part of closed-loop resource systems. CSP is positioned as a cornerstone technology for sustainable space infrastructure, enabling humankind to build resilient habitats and functional systems beyond Earth.