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From Lunar Dust to Lunar Cities: Engineers Turn the Moon’s Harsh Surface into a Blueprint for Settlement
As NASA prepares for humanity’s return to the Moon, researchers at Texas A&M University are exploring how the same material could become a key building block for the first permanent settlements beyond Earth.
The Moon’s surface is surprisingly unlike anything we would consider soil on Earth. Instead, it is covered by a fine powder of pulverized rock and jagged glass that slips into every gap, grinds through seals and gaskets, and exists in a vacuum exposed to intense radiation and extreme temperature swings capable of bending steel. Yet researchers at Texas A&M University see opportunity rather than obstacles in this harsh environment.
Scientists refer to this material as lunar regolith, and it is considered one of the greatest challenges to long-term human habitation beyond Earth.
As NASA advances plans for a permanent human presence on the Moon through its Lunar Innovation Park initiative, Texas A&M researchers are developing technologies designed to transform the lunar surface into a foundation for future settlements.
“We are moving past the era of ‘flags and footprints,’” said Dr. Patrick Suermann, professor of construction science and retired U.S. Air Force lieutenant colonel in a statement. “We have to stop thinking like explorers and start thinking like settlers.”
Money as a Hurdle
Arguably, the greatest challenge facing lunar construction may not be engineering, but cost. Transporting materials from Earth remains extraordinarily expensive, with estimates ranging from roughly $1 million to $1.3 million per kilogram delivered to the Moon. As a result, researchers are increasingly focused on utilizing resources already available on the lunar surface rather than transporting materials from Earth.
“The future depends on building infrastructure from resources already on the moon,” explained Suermann.
“The high cost of shipping to the moon is the million-dollar problem,” Suermann said. “Every time you can cut the mass of a payload, you save a fortune. That’s why the future depends on building infrastructure from resources already on the moon.”
Helping advance that vision is Dr. Robert Ambrose of the Texas A&M Space Institute, located near NASA’s Johnson Space Center in Houston. The institute has received $200 million in support from the Texas Legislature.
“One of the most exciting features of the 240-acre facility is it’s two-and-a-half acre testing areas: one replicating the surface of the moon, the other Mars,” says Suermann.
These facilities allow researchers to evaluate robotic systems, autonomous vehicles, and construction technologies under conditions similar to those expected during future lunar and Martian missions.
Meanwhile, the university’s Construction Automation, Safety and Education (CASE) Lab is exploring how humans and machines can collaborate in extreme environments. Led by Dr. Gilles Albeaino, the lab focuses on mixed-reality technologies and semi-autonomous robotic systems capable of performing construction tasks on the Moon.
“On the moon, construction operations will depend on semi-autonomous robotic systems,” Suermann said. “The CASE lab is leading research into how humans and machines can work together in environments where humans can’t safely do everything themselves.”
“Every tool matters. Every ounce of material you ship matters,” added Suermann. “So, the question becomes: how do you use the environment itself as your supply chain, and how can you augment machines to become your partner in austere environments?”
Arctic to Afghanistan
Suermann’s experience combines two worlds: military service and construction science. Before joining Texas A&M in 2017, he served in the U.S. Air Force, deploying to remote locations that included Afghanistan, Guam, and Greenland.
Those experiences operating in challenging and isolated environments continue to inform his thinking about future lunar settlements.
“My experiences in serving the U.S. Air Force were formative and transformative,” Suermann said. “It taught me a great deal about construction, and that what can go wrong will go wrong.”
It shows, to me, that lunar regolith isn’t too dissimilar from the terrain we have here on Earth,” Suermann adds. “At the end of the day, construction is construction.”
Should We Develop on the Moon?
The broader question remains whether humanity should be expanding its footprint beyond Earth at all. While plans for lunar settlements continue to advance, critics point out that many environmental, political, and social challenges remain unresolved here at home.
As governments and private companies invest billions into space infrastructure, some argue that humanity must carefully consider how development beyond Earth aligns with priorities on our own planet. Others contend that technologies developed for lunar habitation could ultimately provide benefits back on Earth, helping address challenges ranging from resource management to sustainability.
Chrissy Newton is a PR professional and founder of VOCAB Communications. She hosts the Rebelliously Curious podcast, which can be found on The Debrief’s YouTube Channel. Follow her on X: @ChrissyNewton and at chrissynewton.com.
