Designing the bioproduction of Martian rocket propellant via a biotechnology-enabled in situ resource utilization strategy

Mars colonization demands technological advances to enable the return of humans to Earth. Shipping the propellant and oxygen for a return journey is not viable. Considering the gravitational and atmospheric differences between Mars and Earth, we propose bioproduction of a Mars-specific rocket propellant, 2,3-butanediol (2,3-BDO), from CO₂, sunlight and water on Mars via a biotechnology-enabled in situ resource utilization (bio-ISRU) strategy. Photosynthetic cyanobacteria convert Martian CO₂ into sugars that are upgraded by engineered Escherichia coli into 2,3-BDO. A state-of-the-art bio-ISRU for 2,3-BDO production uses 32% less power and requires a 2.8-fold higher payload mass than proposed chemical ISRU strategies, and generates 44 tons of excess oxygen to support colonization. Attainable, model-guided biological and materials optimizations result in an optimized bio-ISRU that uses 59% less power and has a 13% lower payload mass, while still generating 20 tons excess oxygen. Addressing the identified challenges will advance prospects for interplanetary space travel.