A settlement is a mass balance with a 26-month delivery schedule
Whatever the crew consumes and does not regenerate or make locally must be launched from Earth, landed, and stored until the next window.
Closing a loop trades consumable mass for hardware mass and power. On the ISS, where cargo arrives every few months, that trade is about cost. On Mars it is about survival: the loop must keep closing for two years with only what was brought.
Get there
Transport sets the price of every kilogram the settlement does not make for itself, and the calendar: Earth and Mars line up for a launch about every 26 months.
- Measure
- Cost per kilogram landed, landed mass per window, transit time
- Failure boundary
- A cheap ride to orbit that does not become a cheap, reliable landing on Mars
What the record shows at this step
- Reported evidence
- No payload heavier than about a tonne has landed on Mars; Perseverance, the heaviest, was about 1 tonne.
- Where it is moving
- Fully reusable heavy transport refuelled in orbit, landing tens of tonnes per ship (Target).
- Principal risk
- A cheap ride to orbit that does not become a cheap, reliable landing on Mars
Evidence statements describe missions, experiments, and published results. “Where it is moving” is an editorial reading of direction, not an announced capability.
Shelter
A pressurised volume at room temperature, on a planet with an atmosphere under 1% of Earth's pressure, an average near −60 °C, and no magnetic field.
- Measure
- Habitable volume per landed tonne, dose per day inside, leak rate
- Failure boundary
- Leaks, thermal cycling, and radiation dose that accumulate over a long stay
What the record shows at this step
- Reported evidence
- Curiosity measured about 0.7 mSv a day on the surface and about 1.8 mSv a day during cruise.
- Where it is moving
- Habitats covered with regolith or water, and construction printed from local material.
- Principal risk
- Leaks, thermal cycling, and radiation dose that accumulate over a long stay
Evidence statements describe missions, experiments, and published results. “Where it is moving” is an editorial reading of direction, not an announced capability.
Power
Every other loop draws on it. Oxygen, heat, water processing, and above all lit crops turn into kilowatts per person.
- Measure
- Continuous kilowatts delivered, mass per kilowatt, output through a dust storm
- Failure boundary
- A weeks-long dust storm that halves solar output while crops and heaters still need power
What the record shows at this step
- Reported evidence
- A 2018 NASA test reactor produced 1 kW of electricity; a 40 kW lunar fission system is a target.
- Where it is moving
- Surface fission reactors, with solar and storage as supplements.
- Principal risk
- A weeks-long dust storm that halves solar output while crops and heaters still need power
Evidence statements describe missions, experiments, and published results. “Where it is moving” is an editorial reading of direction, not an announced capability.
Air
Oxygen for breathing, CO₂ removal, and trace-contaminant control. On Mars, oxygen can come from the atmosphere rather than being recycled.
- Measure
- Oxygen per day, energy per kilogram, hours between failures
- Failure boundary
- A system that works in short runs but degrades over thousands of hours
What the record shows at this step
- Reported evidence
- MOXIE made 122 g of oxygen in 16 runs on Mars (2021-2023), at up to 12 g an hour and 98% purity.
- Where it is moving
- Solid-oxide electrolysis scaled roughly a hundredfold for crews and return propellant.
- Principal risk
- A system that works in short runs but degrades over thousands of hours
Evidence statements describe missions, experiments, and published results. “Where it is moving” is an editorial reading of direction, not an announced capability.
Water
Drinking, food preparation, hygiene, and, if crops are grown, many times more for irrigation and transpiration.
- Measure
- Recovery rate, spares per year, ice extracted per day
- Failure boundary
- Microbial growth and hardware wear with no replacement parts closer than 26 months
What the record shows at this step
- Reported evidence
- The ISS recovered 98% of its water in 2023, after the brine processor was added.
- Where it is moving
- Ice mining at mid-latitude sites, which turns recycling losses into a mining problem.
- Principal risk
- Microbial growth and hardware wear with no replacement parts closer than 26 months
Evidence statements describe missions, experiments, and published results. “Where it is moving” is an editorial reading of direction, not an announced capability.
Food
The largest remaining consumable once air and water are closed. Growing it requires light, pressurised volume, nutrients, pollination, and a buffer against crop failure.
- Measure
- Share of calories grown, growing area and power per person, harvest reliability
- Failure boundary
- A failed harvest with no resupply for two years
What the record shows at this step
- Reported evidence
- Flight crops are supplements. On the ground, Lunar Palace 365 grew 73% of its food dry mass inside the habitat for a year.
- Where it is moving
- High-yield dwarf crops, algae and insects for protein, and greenhouses lit partly by sunlight.
- Principal risk
- A failed harvest with no resupply for two years
Evidence statements describe missions, experiments, and published results. “Where it is moving” is an editorial reading of direction, not an announced capability.
Nutrients and microbes
Waste must become fertiliser, and the microbiome of crew, crops, and habitat must stay stable. This is where a greenhouse becomes an ecosystem.
- Measure
- Nitrogen recovered, solid waste processed, pathogen and contaminant levels
- Failure boundary
- Slow, invisible drift: soil respiration, gas imbalances, or microbial blooms
What the record shows at this step
- Reported evidence
- Lunar Palace 365 recovered about 67% of solid waste. Biosphere 2 lost oxygen to soil microbes and concrete.
- Where it is moving
- Compartmentalised microbial reactors, as in ESA's MELiSSA, that keep each process controllable.
- Principal risk
- Slow, invisible drift: soil respiration, gas imbalances, or microbial blooms
Evidence statements describe missions, experiments, and published results. “Where it is moving” is an editorial reading of direction, not an announced capability.
What a Mars crew must bring from Earth
A conjunction-class Mars mission lasts about 900 days: roughly six months each way and more than a year on the surface waiting for the planets to realign. There is no resupply in between. Every kilogram not regenerated or made locally must be launched, landed, and stored.
63% less than a fully open loop (22 t)
- Food
- 6.5 t · 79%
- Water
- 0.3 t · 3%
- Oxygen
- 1.5 t · 18%
- Person-days
- 3,600
Step through the scenarios. ISS-class recycling cuts the bill by nearly two-thirds, and once water and oxygen come from Mars, food is essentially all that remains. That is why the frontier has moved from recycling machinery to growing crops, and why growing crops turns into a power problem.
Calculation & assumptions
Consumables = crew × days × (0.84 kg oxygen × unrecovered share + 3.5 kg water × unrecovered share + 1.8 kg packaged food × share not grown). Daily needs are rounded from NASA baseline values; hygiene water, spares, clothing, and propellant are excluded.
The model counts consumables only. Recycling, oxygen production, ice mining, and crop systems all have hardware mass, spares, and power that are not shown, so the real saving is smaller, and it grows with mission length: the longer the stay, the more a closed loop pays back its hardware.
The ISS proves that people can live for decades inside a machine. It does not prove they can live inside one that nobody can resupply.
How the bottleneck moved
Life support progressed in the order of mass saved per engineering effort: water first, then oxygen. What remains is the hardest part of the loop, because it is alive.
Water closed first
Water is chemically simple to purify and heavy to carry, so it repaid engineering first. Recovery went from zero on Apollo to 98% on the ISS.
Mars makes oxygen a supply problem
The atmosphere is 95% CO₂. Splitting it needs power, not recycling, so oxygen stops depending on how perfectly the loop closes.
Food is what is left
With water and oxygen closed or produced locally, about four-fifths of what a crew must bring is food. No spacecraft has grown a meaningful share of its crew's calories.
Food is a photon problem
Plants turn a few percent of light into edible energy. Growing half a diet for four people with electric light needs tens of kilowatts, more than any power system yet flown to another planet.
Growing food costs far more power than making air
Splitting CO₂ for oxygen has a hard thermodynamic floor of about 5 kWh per kilogram, and even MOXIE-class hardware sits within a factor of ten of it. Food has no such shortcut: plants turn only a few percent of light into edible energy, so a lit greenhouse costs kilowatts per person.
84% of it for lighting crops
- Per crew member
- 6.5 kW
- Food energy grown
- 271 W
- Oxygen made
- 3.4 kg/day
- Oxygen at the floor
- 0.69 kW
Sunlight can replace some lamps, but Martian surface light is weaker than Earth’s, arrives through a pressure shell, and can be cut for weeks by dust storms. A settlement that depends on crops must either oversize its power plant or keep a stored-food reserve large enough to ride out a failed harvest.
The floors are known. The gaps are engineering.
Oxygen is near its floor in principle and short of it in practice by a manageable factor. Food is far from any floor that matters, because the conversion from electricity to edible calories is set by crop biology. The runway there is in crop breeding, lighting, and using sunlight directly, not in better pumps.
The discovery chain
Two traditions developed in parallel: machines that recycle in orbit, and sealed biological habitats on the ground. A Mars settlement needs both to meet.
- 1968-1972
Open loop
Apollo carried its oxygen, food, and CO₂ absorbent, and took its water from the fuel cells. Nothing was regenerated.
- 1972-1973
The first sealed ecosystems
BIOS-3 in Krasnoyarsk kept three-person crews for up to 180 days on algae- and crop-regenerated air, with part of the diet grown inside.
- 1991-1993
Biosphere 2
Eight people spent two years in a 1.27-hectare sealed world. Oxygen fell to about 14%, and the lesson was that a biosphere is harder to balance than to build.
- 2008-2010
Physico-chemical recycling in orbit
The ISS began turning urine and humidity into drinking water, and a Sabatier reactor started recovering oxygen from exhaled CO₂.
- 2015-2017
Crops in orbit
Astronauts ate the first lettuce grown on the ISS; the Advanced Plant Habitat followed with a closed, sensor-dense growth chamber.
- 2018-2024
Year-long closure on the ground
Lunar Palace 365 ran for 370 days at 98.2% closure; NASA's first CHAPEA crew lived 378 days in a 3D-printed Mars habitat analogue.
- 2021-2023
Oxygen from Mars
MOXIE ran 16 times on Perseverance, making oxygen from the Martian atmosphere day and night, across seasons.
Why not terraform?
Mars’s surface pressure is about 6 millibars, under 1% of Earth’s. A 2018 inventory of the planet’s accessible carbon dioxide, in polar caps, soils, and minerals, found that releasing all of it would raise pressure to perhaps 20 millibars: still far too thin to breathe, to keep water liquid for long, or to walk outside without a pressure suit. Later proposals to warm the planet with engineered particles are interesting physics, but they address temperature rather than pressure or oxygen, and they are hypotheses, not programmes.
The ecosystems Mars can support in any plannable future are inside pressurised volumes. That makes the relevant curves the ones in this report: closure, power, and reliability, not planetary engineering. There is also a question engineering cannot answer: whether Mars should be altered before it has been searched thoroughly for life of its own.
Who is building what
Agencies and research institutes hold most of the flight and long-duration evidence. Companies are building the transport, construction, and oxygen hardware a settlement would depend on. Search the record, or filter by what they build.
NASAISS ECLSS, MOXIE, Veggie and APH, CHAPEAPhysico-chemical life support in orbit, oxygen from Martian air, plant growth in flight, and year-long Mars-habitat analogues
- Reported evidence
- ISS water recovery reached 98% in 2023; MOXIE made 122 g of oxygen on Mars in 16 runs; the first CHAPEA crew lived 378 days in a 3D-printed Mars habitat analogue.
- Announced next step
- Lunar surface systems under Artemis as the proving ground for Mars life support, power, and habitats.
- Unresolved risk
- Budget and schedule pressure on surface systems, and no flight-tested food or oxygen-closure system sized for a Mars crew.
ESAMELiSSAA compartmentalised microbial and plant loop that turns waste into oxygen, water, and food
- Reported evidence
- A pilot plant in Barcelona has run linked compartments continuously with animal crews standing in for humans; components have flown as experiments.
- Announced next step
- Integrated higher-plant and microbial compartments at human scale.
- Unresolved risk
- Each added compartment adds failure modes; loop stability at full closure with a human crew is not shown.
Beihang UniversityLunar Palace 1Ground-based bioregenerative habitat with crops, insects, and microbial waste treatment
- Reported evidence
- The 370-day Lunar Palace 365 mission reported 100% oxygen and water regeneration, 73% of food dry mass grown inside, and 98.2% overall closure.
- Announced next step
- A lunar base life-support design derived from the facility.
- Unresolved risk
- Ground gravity, abundant Earth power, and no radiation; mass and power were never constrained to flight levels.
Institute of Biophysics, KrasnoyarskBIOS-3Sealed algae and crop habitat, the first long human closed-ecosystem runs
- Reported evidence
- Three-person crews lived up to 180 days (1972-1973) with about 91% overall regeneration.
- Announced next step
- Historic; the data remain a baseline for bioregenerative design.
- Unresolved risk
- Relied on stored food for part of the diet and on external power and heat rejection.
SpaceXStarshipFully reusable methane-oxygen transport, with return propellant made on Mars from CO₂ and ice
- Reported evidence
- Suborbital and orbital-velocity test flights of the full stack, booster catches, and in-flight propellant-transfer development.
- Announced next step
- Uncrewed Mars landings in an upcoming launch window, followed by crews (Target).
- Unresolved risk
- Orbital refilling at scale, landing heavy payloads on Mars, and a propellant plant that has only been demonstrated at gram scale.
Collins AerospaceISS oxygen, water, and CO₂ systemsElectrolysis, water processing, and Sabatier reduction (Hamilton Sundstrand heritage)
- Reported evidence
- Hardware behind the ISS Oxygen Generation Assembly, Water Recovery System, and the Sabatier reactor that recovers about half the oxygen in exhaled CO₂.
- Announced next step
- Lighter, more reliable exploration-class life support.
- Unresolved risk
- ISS hardware depends on frequent spares and crew maintenance that a Mars mission cannot resupply.
OxEon EnergyMOXIE electrolysis stackSolid-oxide cells that split CO₂ into oxygen and carbon monoxide
- Reported evidence
- Built the solid-oxide stack (as Ceramatec) that ran MOXIE at up to 12 g of oxygen an hour at 98% purity on Mars.
- Announced next step
- Stacks scaled roughly two orders of magnitude for crew and propellant production.
- Unresolved risk
- Thermal cycling, dust, and degradation across thousands of hours, rather than 16 short runs.
Sierra SpaceVeggie, Advanced Plant Habitat, TCPS, LIFEPlant-growth chambers, trash-to-resource processing, and inflatable habitats
- Reported evidence
- Its ORBITEC heritage built Veggie and the Advanced Plant Habitat that have grown crops on the ISS since 2015 and 2017.
- Announced next step
- Inflatable LIFE habitat modules for commercial stations and beyond.
- Unresolved risk
- Flight plant growth is supplemental: grams of salad, not a diet.
Interstellar LabEden and BioPod modulesModular controlled-environment growth units for space and Earth
- Reported evidence
- Terrestrial pods and NASA-supported research on compact bioregenerative food production.
- Announced next step
- Plant modules suited to lunar and Mars habitats.
- Unresolved risk
- Power per kilogram of food, and proving closure rather than growth.
Paragon Space DevelopmentCommercial ECLSSThermal and life-support systems for crewed vehicles and stations
- Reported evidence
- Founded by Biosphere 2 veterans; supplies thermal control and life-support subsystems to commercial spaceflight programmes.
- Announced next step
- Closed-loop systems for commercial stations and surface habitats.
- Unresolved risk
- Commercial demand for high-closure systems is thin while low-Earth orbit can still be resupplied.
ICONMars Dune Alpha, Project OlympusRobotic 3D printing of structures from local material
- Reported evidence
- Printed the 158 m² Mars Dune Alpha analogue habitat for NASA's CHAPEA; holds a NASA contract to develop lunar surface construction.
- Announced next step
- Printing landing pads and shelters from lunar regolith.
- Unresolved risk
- Binders, curing in vacuum and cold, and dust are unsolved off Earth; nothing has been printed on another world.
AI SpaceFactoryMARSHAPrinted habitat shells from basalt fibre and plant-derived polymer
- Reported evidence
- Won NASA's 3D-Printed Habitat Challenge in 2019 with a printed, pressure-tested subscale structure.
- Announced next step
- Regolith-based construction for lunar and Mars shelters.
- Unresolved risk
- The winning material relied on imported binder; true local construction needs local binders.
Blue OriginBlue AlchemistMolten-regolith electrolysis that yields metals, silicon for solar cells, and oxygen
- Reported evidence
- Announced production of solar cells and oxygen from lunar regolith simulant in 2023.
- Announced next step
- Lunar power and oxygen made on the surface.
- Unresolved risk
- Very high temperatures and electrode life; lunar chemistry differs from Mars, where oxygen is easier to pull from the air.
COSPARPlanetary protection policyInternational guidance on biological contamination of other worlds
- Reported evidence
- Mars landers are categorised by where they go and whether they search for life; human missions are still under active policy development.
- Announced next step
- Rules for crewed missions that will inevitably carry microbes.
- Unresolved risk
- Every open ecosystem leaks; policy may constrain where habitats can go and what they can vent.
Capabilities are reproduced from missions, publications, and public announcements. An announced landing date is a Target, and a demonstration on Earth or the Moon is not a result on Mars.
The remaining constraints are power, reliability, and biology
The field has moved from carrying everything, to recycling water and air, to the problem of feeding people from a system that must run for years without help.
Reliability without resupply
The ISS keeps its life support running with spares shipped every few months. A Mars crew has one delivery every 26 months, so mean time between failures, repairability, and on-site manufacturing of parts matter more than peak efficiency.
Power
Crops, oxygen, heat, and water processing all draw on it. Nothing flown to Mars has produced more than a few hundred watts; a settlement needs tens to hundreds of kilowatts through dust storms.
Food at scale
Growing a diet has only been demonstrated on Earth, with Earth power, gravity, and repair crews next door. Crop yield at Mars gravity and under Mars light is unmeasured.
Radiation
A 900-day mission can approach NASA's 600 mSv career limit before any shielding advantage from habitats is counted.
Ecological stability
Closed biological systems drift. Biosphere 2's oxygen problem took over a year to diagnose. A settlement needs sensing and control that keep dozens of coupled processes stable.
Planetary protection
Crewed habitats will leak microbes. Rules for where they can go and what they can vent, especially near ice that might hold evidence of life, are unsettled.
What pushes the curves next
Surface fission power
Tens of kilowatts that do not care about dust storms turn crops and oxygen plants from luxuries into baseline systems.
Condition: a reactor flown and run on the Moon firstOxygen plants scaled up
Solid-oxide electrolysis roughly a hundred times MOXIE’s output, running for years, supplies breathing oxygen and the oxidiser for the trip home.
Condition: stack lifetime through thousands of thermal cycles and dusty intake airCrops bred for closed systems
Dwarf, high-harvest-index varieties and protein from algae or insects raise edible calories per watt and per square metre.
Condition: yield measured under partial gravity and realistic lightMaintainable, printable hardware
Life support designed to be repaired with parts printed on site shortens the chain of failures that a 26-month resupply gap cannot tolerate.
Condition: printable materials that meet pressure-vessel and medical standardsAn optimistic view, with conditions
A Mars base needs a greenhouse and a reactor, not a new physics
Every loop has a working demonstration somewhere: 98% water recovery in orbit, oxygen from Martian air, a year of 98% closure on the ground. None has been integrated, scaled, and run without help on another world. If transport costs keep falling and surface fission power flies, the remaining work is engineering integration and endurance testing, done first on the Moon, where help is three days away.
Prove the parts on the Moon
Surface power, oxygen extraction, and small plant-growth systems operating for months on the lunar surface. Continued ground analogues at flight-realistic power.
Pre-deployed plants on Mars
Uncrewed landings that set up power, oxygen, and water production before a crew arrives, so the return propellant exists before anyone depends on it.
A base that feeds itself
Most calories grown on site, stored-food reserves for failed harvests, and resupply shrinking toward spare parts and seeds.
View the annual scorecard
| Metric | Record through September 2026 | What a self-sustaining base needs |
|---|---|---|
| Water recovery in flight | 98% (ISS, 2023) | 98%+ for years with little resupply |
| Oxygen from exhaled CO₂ in flight | About 50% (ISS Sabatier) | Near-complete, or replaced by local production |
| Oxygen made on Mars | 12 g an hour peak; 122 g in total | Kilograms an hour for years |
| Food grown, flight | Supplements only | A majority of calories |
| Food grown, ground analogue | 73% of dry mass for a year (Lunar Palace 365) | Most calories at flight-realistic power and mass |
| Surface power | Hundreds of watts (rovers) | Tens to hundreds of kW, dust-storm proof |
Baselines are reported results. Targets are editorial benchmarks, not forecasts.
There is more than one finish line
- SurviveA crew lives on Mars on supplies brought from Earth.
- RecycleWater and air loops close at ISS levels, without resupply.
- ProduceOxygen, water, and return propellant come from Mars.
- GrowA majority of calories are harvested on site.
- RepairMost failures are fixed with parts made on site.
- SustainThe base grows without needing more from Earth each window.
Sources, method, and boundaries
Figure 1 plots reported recovery rates for flight hardware and food shares for ground habitats; the ground values for BIOS-3 and Biosphere 2 are approximate. Figures 3 and 4 are illustrative models with daily needs rounded from NASA baseline values. Evidence labels follow the house standard: Measured (directly demonstrated), Derived (calculated from measured data), Projected (modeled future outcome), Target (announced goal), and Editorial inference (interpretation of evidence). Company and agency dates are Targets unless stated otherwise.
- Closure
- The share of a consumable that is regenerated inside the system rather than resupplied.
- ISRU
- In-situ resource utilisation: making oxygen, water, propellant, or building material from local resources.
- Sabatier reaction
- CO₂ + 4H₂ → CH₄ + 2H₂O. On the ISS it recovers water from exhaled CO₂; on Mars it could make methane propellant.
- Conjunction-class mission
- A Mars round trip of about 900 days, including a surface stay of more than a year while the planets realign.



















