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NASA NTRS2012

On Applications of Disruption Tolerant Networking to Optical Networking in Space

The integration of optical communication links into space networks via Disruption Tolerant Networking (DTN) is a largely unexplored area of research. Building on successful foundational work accomplished at JPL, we discuss a multi-hop multi-path network featuring optical links. The experimental test bed is constructed at the NASA Glenn Research Center featuring multiple Ethernet-to-fiber converters coupled with free space optical (FSO) communication channels. The test bed architecture models communication paths from deployed Mars assets to the deep space network (DSN) and finally to the mission operations center (MOC). Reliable versus unreliable communication methods are investigated and discussed; including reliable transport protocols, custody transfer, and fragmentation. Potential commercial applications may include an optical communications infrastructure deployment to support developing nations and remote areas, which are unburdened with supporting an existing heritage means of telecommunications. Narrow laser beam widths and control of polarization states offer inherent physical layer security benefits with optical communications over RF solutions. This paper explores whether or not DTN is appropriate for space-based optical networks, optimal payload sizes, reliability, and a discussion on security.

Hylton, Alan Guy↗

NASA NTRS2021

Cislunar Autonomous Positioning System Technology Operations and Navigation Experiment (CAPSTONE)

NASA has partnered with Advanced Space to develop and build the Cislunar Autonomous Positioning System Technology Operations and Navigation Experiment (CAPSTONE) mission which will serve as a pathfinder for Near Rectilinear Halo Orbit (NHRO) operations around the Moon. The NHRO, (Perilune = 3,200 km; Apolune = 70,000 km) will be the intended orbit for the NASA’s Artemis Gateway lunar orbital platform. The CAPSTONE mission will validate simulations and confirm operational planning for Gateway while also validating performance of navigation and station-keeping requirements for the Power and Propulsion Element. Thus, this mission will provide operational experience to NASA, commercial, and international missions for operations in a demanding orbital regime. The baseline for CAPSTONE is to fly a 12U cubesat developed, integrated, and tested by Tyvak Nanosatellite Systems carrying a payload communications system capable of cross-link ranging with the Lunar Reconnaissance Orbiter (LRO), a dedicated payload flight computer for software demonstration, and a camera. The launch, coordinated by NASA Launch Services Program, will be provided by a Rocket Lab launch vehicle utilizing their new Proton upper stage to deploy the CAPSTONE spacecraft into the lunar orbit. The CAPSTONE mission is targeting a launch no earlier than September 23, 2021. Upon launch, the spacecraft will traverse a highly efficient transfer taking approximately three months to enter a primary demonstration phase in an NRHO for six months followed by a twelve month technology enhancement operations phase. The CAPSTONE Project is lead by Advanced Space, LLC of Boulder Colorado. Spacecraft development and mission operations will be conducted by Tyvak Nanosatellite Systems of Irvine, California. Noted objectives for the CAPSTONE mission will be to demonstrate the accessibility of NHROs, validate key operational concepts in the NHRO environment, lay a foundation for commercial support of future lunar operations and accelerate the availability of peer-to-peer navigation capabilities provided by the Cislunar Autonomous Positioning System (CAPS). The CAPSTONE mission is funded through NASA's Small Spacecraft Technology Program (SSTP), which is one of several programs in NASA’s Space Technology Mission Directorate. SSTP is chartered to develop and demonstrate technologies to enhance and expand the capabilities of small spacecraft with a particular focus on enabling new mission architectures through the use of small spacecraft, expanding the reach of small spacecraft to new destinations, and augmenting future missions with supporting small spacecraft. The launch for the CAPSTONE Mission is provided by Human Exploration & Operations Missions Directorate Advanced Exploration Systems Division. Coordination and Acquisition of the Launch is managed by NASA’s Launch Services Program. The CAPSTONE Mission and project status will be presented.

CAPSTONE↗

NASA NTRS2021

Cislunar Autonomous Positioning System Technology Operations and Navigation Experiment (CAPSTONE) Mission

CAPSTONE↗

DOE OSTI2022

Chapter 11: Biochar Production

In production of biochar, thermochemical processes that can be used to treat biomass include pyrolysis, gasification, hydrothermal processing, and combustion. Each of these processes is defined by specific operating conditions (e.g., temperature, presence of oxygen) and feedstock requirements for optimal conversion to the product of primary interest. Each process results in varying fractions of gaseous, liquid, and solid products. Though other publications have emphasized the gaseous bio-energy products of such processes (e.g., bio-oil, synthesis gas or "syngas") with biochar as a co-product, in this discussion, we focus primarily on biochar as the In production of biochar, thermochemical processes that can be used to treat biomass include pyrolysis, gasification, hydrothermal processing, and combustion. Each of these processes is defined by specific operating conditions (e.g., temperature, presence of oxygen) and feedstock requirements for optimal conversion to the product of primary interest. Each process results in varying fractions of gaseous, liquid, and solid products. Though other publications have emphasized the gaseous bio-energy products of such processes (e.g., bio-oil, synthesis gas or "syngas") with biochar as a co-product, in this discussion, we focus primarily on biochar as the main product, with heat and electrical energy as co-products of secondary interest. The reasons for this are as follows: when producing biochar, heat is the simplest form of energy to capture and utilize, electrical energy can be generated from heat energy with a wide range of available technologies small and large; rather than immediately combusting the gases released from biomass, there is potential to refine the gases into bio-oil and syngas. However, much larger investments of capital are needed to build facilities for which gaseous fuel production is the primary goal, as compared to those focused on biochar production with heat and electrical energy co-products. While the economic viability of biochar production will be improved by production of high-value co-products (e.g., wood acids for use in pesticides), the simplest production scheme is one in which biochar and heat are the primary products. Here we aim to provide a broader overview of thermochemical processes and technologies most relevant to biochar production in its current state of commercialization. All biochar is a result of pyrolysis (the reaction) but not all biochar is made with a dedicated pyrolysis reactor (the technology type). Further, all biochar is the result of a lack of complete combustion (the reaction), even biochar produced in a combustion or gasification reactor (the technology type). This is an important distinction to acknowledge in the following sections in which we discuss both thermochemical conversion reactions and technology types.

biochar↗

DOE OSTI2024

Equity Considerations in Siting Consolidated Interim Storage Facilities for Commercial Spent Nuclear Fuel

Questions of equity and fairness are often raised by representatives from State, Tribal and local governments and members of the public when resolving conflicts over siting of nuclear facilities. However, the two terms are not synonymous: equity can be quantified while fairness is much more subjective. The Department of Energy's (DOE) December 2021 Request for Information sought input on how to site federal facilities for the temporary, consolidated storage of spent nuclear fuel (SNF) using a consent-based approach. It is anticipated that just such questions about equity and fairness associated with the potential emergence of more than one host site may be raised by the twelve groups of university, nonprofit and private sector partners (Consortia) working to support community engagement, inclusively involve stakeholders, build relationships, and develop innovative forms of mutual learning and public capacity to participate in the consent-based siting process for a federal consolidated interim storage facility during the current Planning & Capacity Building stage of the consent-based siting process. In terms of DOE's Integrated Waste Management System (IWMS), sociopolitical equity concepts are a factor in all aspects of IWMS development and operations and will be particularly applicable should two or more host sites become a possibility, either by the emergence of multiple volunteer hosts or by pursuit as a IWMS program strategy. This paper summarizes recent analyses that explore how four equity metrics - number of states, division of the projected SNF total by the year 2083, current population and land area - might be perceived by host communities, states and regions if two, three or four sites for hosting federal consolidated interim storage facilities were to be contemporaneously realized. Existing institutional arrangements, including Nuclear Regulatory Commission regions, Federal Energy Regulatory Commission regions and Low-Level Radioactive Waste Disposal Compacts, were selected to create hypothetically merged two, three and four-region scenarios to calculate how the four metrics balance out. Projected SNF burden was prioritized with regional contiguity of the consolidated regions a requirement for a functional scenario. The intent was not to promote or suggest any construct as a program objective; the configurations are geopolitical abstractions only to explore potential perceptions of equity. Understanding the possible issues of equity that could arise may benefit program efforts toward achieving a cooperative federalism wherein both the federal and multiple State governments share the goal of manifesting more than one federal consolidated interim storage facility. The main finding is that it is not possible to optimize for all four metrics simultaneously. The analyses demonstrate that trying to create a sense of equity by backfitting a solution to a random population and land distribution will always contain a degree of artificiality.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

NASA NTRS2018

Understanding Risk Tolerance and Building an Effective Safety Culture

Estimates range from 65-90 percent of catastrophic mishaps are due to human error. NASA's human factors-related mishaps causes are estimated at approximately 75 percent. As much as we'd like to error-proof our work environment, even the most automated and complex technical endeavors require human interaction... and are vulnerable to human frailty. Industry and government are focusing not only on human factors integration into hazardous work environments, but also looking for practical approaches to cultivating a strong Safety Culture that diminishes risk. Industry and government organizations have recognized the value of monitoring leading indicators to identify potential risk vulnerabilities. NASA has adapted this approach to assess risk controls associated with hazardous, critical, and complex facilities. NASA's facility risk assessments integrate commercial loss control, OSHA (Occupational Safety and Health Administration) Process Safety, API (American Petroleum Institute) Performance Indicator Standard, and NASA Operational Readiness Inspection concepts to identify risk control vulnerabilities.

Loyd, David↗

DOE OSTI2022

Permanent Foam Fixatives for Radioactive Contamination Control: Environmental Chamber Testing

The Department of Energy (DOE) Office of Environmental Management (EM) is tasked with closing cleanup sites throughout the DOE-EM complex. A major component of successfully closing the sites is the deactivation and decommissioning (D&D) of radioactively contaminated buildings in nuclear facilities. Deactivation consists of the process of placing a contaminated facility in stable condition in order to minimize any risks that could affect workers, the public, and the environment. Successful deactivation and decommissioning consists of leaving the buildings in an agreed upon end state to provide future protection against hazards. Hazards include radiation but can also include asbestos, polychlorinated biphenyls, and other environmental and physical hazards.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2023

Advanced Algal Biofoundries for the Production of Polyurethane Precursors

The primary goal of the BEEPs project was to develop a process that could accelerate the development of algae as bioproduction platforms, from initial chemical product concept to an economically viable market supply. Under this program we elected to develop strains of algae that could generate polyurethane precursors, while simultaneously developing basic genetic tools to enable improved algal production systems. This program was specifically designed to incorporate National Laboratories as a means to utilize the expertise and facilities for new bio-production platforms. To that end, we designed a program to collaborate with the Agile BioFoundry at Lawrence Berkeley National Laboratory (LBNL) and computational platforms at Pacific Northwest National Laboratory (PNNL). In addition to these National Laboratory partners, we also had academic partners from UC Davis and Georgia Tech, as well as commercial partners Algenesis Materials and BASF. To achieve these goals, we initially focused on developing the genetic tools and high throughput screening technologies necessary to generate and assess production of polymer precursors (succinic acid) in algae and cyanobacteria, including advanced promoters and biosensors. In parallel, we computationally identified potential production bottlenecks and then used the developed genetic tools to increase production rates and yields. Constant feedback of data was used in conjunction with machine learning, high-throughput cell sorting, and synthetic biology, for additional targeted metabolic engineering. Multiple rounds of tool design, building, testing, and learning were supplied to partners at PNNL and LBNL to develop new models and tools that could expedite bioproduction platform development and increase yield performance. We targeted, and achieved, the FOA requirement yield metric of 20 g/L, as a milestone and deliverable from at least one of our engineered strains for the production of succinic acid.

09 BIOMASS FUELS↗

DOE OSTI2024

Demonstration and Evaluation of Explainable and Trustworthy Predictive Technology for Condition-based Maintenance

The domestic nuclear power plant (NPP) fleet has historically relied on labor-intensive and time-consuming predictive maintenance (PdM) programs, thus driving up operation and maintenance (O&M) costs to achieve high-capacity factors. Artificial intelligence (AI) and machine-learning (ML) can help simplify complex problems such as diagnosing equipment degradation to enable more effective decision-making efforts. The benefits of AI will be felt through more efficient plant O&M, improved work processes, and better integration of people and technology. Together, these benefits hold the promise to make nuclear power more sustainable by reducing O&M costs while improving employee engagement. While AI and ML technologies hold significant promise for the nuclear industry, there are challenges or barriers to their adoption. Explainability and trustworthiness of AI are two salient challenges that need to be addressed for wider deployment of these technologies in NPPs. This research focuses specifically on addressing the explainability and trustworthiness of AI technologies to advance the human, technical, and organization (HTO) readiness levels in adopting a risk-informed PdM strategy at commercial NPPs. In addition, this approach can be adapted to enhance the acceptability of AI in other nuclear applications with a few application-specific modifications. The technical approach ensuring wider adoption of AI technologies was developed by Idaho National Laboratory (INL)—in collaboration with Public Service Enterprise Group (PSEG), Nuclear, LLC—by utilizing the circulating water system (CWS) at two PSEG-owned plant sites for demonstration. Focused user studies were performed in collaboration with subject matter experts (SMEs) from PSEG and other nuclear domains to enhance human and organization readiness by building trust in AI-informed technologies. VIsualization for PrEdictive maintenance Recommendation (VIPER)—a Battelle Energy Alliance, LLC, copyrighted software—was developed and expanded to provide a user-centric visualization by incorporating inputs from the collaborating utility, human factors engineering guidelines, and data analysts. The VIPER software enables users, who may be unfamiliar with ML in general, to be interactively engaged by asking technical questions about PdM, work orders, diagnosis results and their confidence levels, the kind of data being used, and the types of ML algorithms employed. This interactive engagement enhances explainability and builds trust. One of the enabling accomplishments was the integration of large language models (LLMs), both text-based and vision-based, in the VIPER software.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2020

Novel, Simplified Air Delivery System Design Gets Commercialized

Typical air delivery systems require contractors to design systems that are complex, difficult to integrate into the framing and structural components of a home, and often do not meet the optimization demands of newer energy-efficient homes. This complex process can be a burden to already strained construction labor costs. However, a new technology simplifies duct system design to improve comfort and eliminate sources of installation error for residential air delivery systems.

Building America↗

DOE OSTI2020

Selective Ligand Modification of Cobalt Porphyrins for Carbon Dioxide Electrolysis: Generation of a Renewable H2/CO Feedstock for Downstream Catalytic Hydrogenation

Catalytic hydrogenation is an attractive approach to produce green fuels and chemicals. The building blocks for these processes may be effectively produced from renewable power via direct electrochemical reduction of carbon dioxide in an aqueous media. For the first time, the impact of increasing the local proton concentration of cobalt porphyrin was examined by synthesizing new cobalt porphyrins 2, Co(o-OCH3)TPP and cobalt porphyrin 3, Co(o-OH)TPP. Cobalt porphyrins coated on carbon paper converted carbon dioxide and water into a mixture of hydrogen and carbon monoxide in an aqueous electrolyte at near neutral pH. Increasing the local proton availability of the commercial cobalt porphyrin 1, accelerates hydrogen generation under heterogeneous conditions across the range of potentials tested (-0.85 to -1.5 V vs. Ag/AgCl) and demonstrates high Faradaic efficiencies (ca. 90%) at low over-potentials (ca. 540 mV). The culmination of this work can help identify key parameters that facilitate generation of sustainable reagents for catalytic hydrogenation under practical and scalable conditions.

BIOMASS FUELS,INORGANIC, ORGANIC, PHYSICAL, AND AN↗

DOE OSTI2021

Perform Life Cycle Energy and GHG Emission Analysis, Select Candidate Refrigerant(s), Developing Heat Pump by Using Low-GWP Refrigerants and 5 mm Diameter Tubes

Reducing environmental impacts from the energy conversion systems has been an important research topic due to recent severe global climate changes. In residential buildings, the space heating and cooling are main energy consumers, which are relying on vapor compression based heat pumps. To mitigate the environmental impacts of residential systems, the heat pumps using low-GWP refrigerants and 5mm-tube heat exchangers are proposed to replace the conventional 9 mm or 7 mm tube heat exchangers. This research uses a simulation-based design method to optimize the refrigerant circuitries of a 5-ton low-GWP refrigerant heat pumps whose indoor and outdoor heat exchangers adopt 5 mm tubes. Heat pump systems using four commercially available low-GWP refrigerants (R454A, R454C, ARM20A and ARM20B) are optimized and compared with the baseline R410A system. The results indicate that directly replacing 9 mm tubes into 5mm tubes in the baseline systems induces heat pump performance degradation; by optimizing the 5 mm tube heat pumps with added tube rows, the system refrigerant charge is reduced up to 33% compared with the baseline; the optimized low-GWP 5 mm tube heat pumps offer the same or higher performance under both cooling and heating mode; that under cooling mode, the EER improvement is up to 10.7% and under heating mode the COP improvement is up to 3.4%; and a smart flow control device to maintain counter-flow circuitry pattern on both operating modes can improve the heating performance of 5 mm tube optimized system by up to 3.0%. In an effort to better understand the environmental impacts of these systems, life cycle climate performance (LCCP) evaluation method is used to assess the baseline and optimized systems. LCCP considers the direct and indirect emissions of the system over the course of its lifetime from manufacturing to disposal. Our analyses indicate that the optimized systems using 5mm tubes and low-GWP refrigerants can reduce life-cycle CO 2 emission significantly. And improving system efficiency is the most effective way to reduce the emission of low-GWP refrigerant systems. This report shows that using 5 mm diameter tubes in heat exchangers is a feasible approach to develop heat pumps with low-GWP refrigerants. Using the proposed design approach can yield higher system efficiency with lower environmental impact.

42 ENGINEERING↗

DOE OSTI2023

Development of a Portable In Situ Phosphorous Sensor

While phosphorus is a critical nutrient for all forms of life, runoff leads to phosphorus accumulation in surface water where it can cause a variety of health, environmental, and economic problems. The Department of Energy is interested in conducting long-term field experiments to monitor the impact of phosphorus in terrestrial and aquatic environments, and to better understand a cost vs. benefit analysis of reducing phosphorus pollution. Performing such long-term experiments requires affordable sensors capable of monitoring low-level phosphorus concentrations under challenging environmental conditions. However, such sensors are currently not available. The goal of this proposed project is to develop and demonstrate a low-cost portable phosphorus sensor suitable for in situ measurements. We will determine the technical requirements for a Raman-based sensor system, design and build a signal amplifier, integrate it with a Raman-based sensor, and demonstrate a proof-of-concept level sensor system. The expected accomplishments for Phase I include the identification of the technical requirements of a combined Raman laser/spectrometer and cavity enhancement system, building a proof-of-concept level sensor system capable of detecting orthophosphate compounds at the desired level of 0.25 mg P/L and organic P compounds, and verification of the sensor performance under laboratory and field conditions. In addition, we will identify initial hardening requirements that will need to be implemented during Phase II. While we plan to develop an integrated sensor system for monitoring phosphorus, the cavity-based enhancement system can also be used in combination with other (non-phosphorus) Raman sensors that we plan to develop or that are already commercially available. A recent market report highlights the increasing demand for such environmental monitoring applications, with the market for chemical detection anticipated to grow at a compound annual growth rate of 6.5% (2020-2025). Wide-spread monitoring of phosphorus could reduce the damage from eutrophication in freshwater, which is estimated to be $2.2 billion annually, thereby increasing biodiversity, reducing costs required for drinking water treatment, and decreasing economic losses related to recreation and angling and lake property values.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2024

Schema Elements for Granta Annual Report: FY2024

Granta: Materials Intelligence (Granta: MI) is a commercial database software distributed by Ansys, Inc. that is utilized by the Nuclear Security Enterprise (NSE) to organize and store relevant materials data. Lack of standard and well-documented database schema is the primary obstacle to an NSE materials data management solution, so the objective of this project is to create and document such a schema. In FY21, an approach for designing, documenting, and managing a standard database schema was described based on the creation of schema elements (collections of attributes used to describe particular aspects of the data) to be used as building blocks for creating various database tables without duplication. In FY22, these methods were applied through a multi-site collaboration to create and document the schema elements necessary to build a thermogravimetric analysis (TGA) testing table. In FY23 the schema was expanded to include elements for a differential scanning calorimetry (DSC) table, along with schema for supporting metadata tables including Instruments, Projects, Documents, and Testing Series. In FY24 the following progress was made, again through multi-site collaboration: • The existing schema elements were modified to accommodate thermomechanical analysis (TMA) data, and a table, Test Data: TMA, was created for managing TMA data. • The elements necessary for the following additive manufacturing (AM) data tables (directed at data specific to selective laser sintering AM technology) were created: • AM Builds • AM Processes • AM Part Designs • Built AM Parts • AM Feedstock Materials • AM Feedstock Material Batches • The elements necessary for creating a Calibrated Material Models table were created, and the Calibrated Material Models table was created. In FY25 the existing schema will be deployed on the production enterprise Granta instance on the enterprise secure network. Schema elements will be appended, and new elements created as necessary, to allow the creation of tables specifically to support materials testing, AM process development, and design and analysis for modernization programs.

36 MATERIALS SCIENCE↗

DOE OSTI2026

Daily operational impacts on battery degradation in heavy-duty electric drayage trucks

Battery aging is a critical factor influencing the performance, longevity, and cost of ownership of battery electric trucks (BETs). This paper presents a comprehensive evaluation of battery aging for two Li-ion battery chemistries, Nickel-Manganese-Cobalt (NMC) and Lithium-Iron-Phosphate (LFP), accounting for both cycling and calendar aging. In contrast to traditional methods that rely on simplified linear degradation models based on manufacturer-provided data, this study employs semi-empirical aging models calibrated to experimentally collected data. The models are integrated into a detailed vehicle simulation environment, enabling a comprehensive assessment of battery degradation under realistic operating conditions. A case study focusing on heavy-duty electric drayage truck operations in the Port of Savannah, GA, is presented to illustrate the impact on battery pack lifespan of: seasonal variations, daily operational activities, charging strategies, and battery storage conditions. The results illuminate the significance of the battery pack’s state of charge during stationary periods, such as overnight storage or weekend parking, on battery degradation and its potential implications for long-term vehicle viability. Additionally, the study explores how different operational and environmental factors affect battery degradation, offering critical insights into best battery charging and storage practices. Our results demonstrate that LFP outperforms NMC in terms of years of useful life; however, by utilizing charging strategies that minimize the amount of time the battery spends resting at high levels of state-of-charge, the lifespan of the battery pack that uses NMC can nonetheless be increased by more than a factor of two.

25 ENERGY STORAGE↗

DOE OSTI2020

Critical Unresolved Region Integral Experiment Execution

Integral Experiments are a key aspect of validating nuclear data behavior and simulation capabilities. Further, integral experiments are the earliest form of validation of equations and codes. They have been used extensively since the 1940s. Today, simulation and predictive capabilities have improved greatly from 75 years ago, but nonetheless, integral experiments are still needed. As simulation capabilities improve, their uncertainties get much smaller. The current focus of many new experiments is understanding the intermediate energy range. The intermediate energy range does not have a wide application space and it can be challenging to design experiments that are sensitive to neutron energies in this region. The Zeus experiments evaluated highly enriched uranium (HEU) in the intermediate energy region. Building on the success and knowledge gained from the Zeus experiments, the Critical Unresolved Region Integral Experiment (CURIE) experiments were designed to evaluate HEU in the narrower unresolved resonance region (URR). These experiments were executed during June and July 2020 at the National Criticality Experiments Research Center (NCERC). The National Criticality Experiments Research Center (NCERC), operated by Los Alamos National Laboratory, is the only general purpose critical experiments facility in the United States of America. NCERC regularly designs and executes critical experiments and other measurements useful to a wide variety of fields including nuclear criticality safety, commercial nuclear energy, nonproliferation, and nuclear data.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

DOE OSTI2025

Nanoporous Wood Chips Based Sizable, Robust, and Low-Cost Honeycomb Vacuum Insulation Panels (DOE BENEFIT Final Research Performance Progress Report (RPPR))

Conventional vacuum insulation panels (VIPs) suffer from severe limitations including high cost, vulnerability to perforation, and significant performance degradation over time due to vacuum loss. InventWood Inc. (IW) and partnering teams completely re-engineered the VIP structure by constructing arrays of isolated vacuum-cells to enable limited cutting at designated areas (in between vacuum cells) and reduced consequential vacuum loss due to puncture. The teams also replaced the expensive vacuum insulation core materials with a low-cost commercial wood pulp and recycled long fiber. The wood pulp derived VIP can deliver an overall panel insulation of R15 (<0.01W/m·K) with over 90% thermal resistance retention after cutting (R13.5 overall, R5 along the cut edges). In addition, the vacuum-cell-array design minimizes edge losses, resulting in more durable performance, longer service life (>50 years), and higher R-value per dollar towards a cost target of <$1/ft 2 ·in. It is anticipated that the Nanochip-VIP will attract strong market interest and become an affordable insulation solution for energy efficient buildings and retrofits, leading to significant reductions in energy usage.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2026

Development of large-scale, 3D Printed high temperature ceramic material

Through this collaborative effort, a new 3D printing platform for ceramics called laser-induced slip casting (LIS) was explored and developed for improving the processing and manufacture of silicon carbide (SiC), a high temperature ceramic material. This method prints layers of ceramic slips/slurries with subsequent selective-laser heating to dry each layer to build a 3D structure. The completed and dried part is then sintered. This manufacturing process is inherently lower cost than alternative ceramic printing methods such as binder jet technology or stereolithography when it comes to the feedstock material but is more expensive than robocasting or direct ink writing. However, it has the potential to make more controlled parts with less defects compared to robocasting. The largest cost is the heating source for the printer. With this technique, there is potential to make large ceramic parts in a near-net shape. Further, there is no known commercial manufacturing of 3D printed ceramics that creates a large range of different high-density ceramics at large scale. The goals and outcomes for the development of the new printing technology were: 1) assessing the technology with alumina by characterizing coupons, 2) printing and sintering of silicon carbide (SiC), and 3) characterization and properties testing of materials printed and a scale-up of SiC part(s). Through this collaborative project, it was sought to provide the best solution to achieving highly dense and near-net shaped ceramic parts at large scale and reduced cost. The goal was to produce high density sintered materials for applications in defense, energy generating systems, armor, and wear parts using 3D printing methods. Variables including powder particle sizes, dispersant molecular weights (MWs), binders, printing parameters, and post processing were explored as well as the characterization of the physical properties (add specifics here).

36 MATERIALS SCIENCE↗

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