Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “Cost reduction”

Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 199 records · Page 11
All sourcesNASA NTRSDOE OSTI
NASA NTRS2007

Imaginable Technologies for Human Missions to Mars

The thesis of the present discussion is that the simultaneous cost and inherent safety issues of human on-site exploration of Mars will require advanced-to-revolutionary technologies. The major crew safety issues as currently identified include reduced gravity, radiation, potentially extremely toxic dust and the requisite reliability for years-long missions. Additionally, this discussion examines various technological areas which could significantly impact Human-Mars cost and safety. Cost reductions for space access is a major metric, including approaches to significantly reduce the overall up-mass. Besides fuel, propulsion and power systems, the up-mass consists of the infrastructure and supplies required to keep humans healthy and the equipment for executing exploration mission tasks. Hence, the major technological areas of interest for potential cost reductions include propulsion, in-space and on-planet power, life support systems, materials and overall architecture, systems, and systems-of-systems approaches. This discussion is specifically offered in response to and as a contribution to goal 3 of the Presidential Exploration Vision: "Develop the Innovative Technologies Knowledge and Infrastructures both to explore and to support decisions about the destinations for human exploration".

Bushnell, Dennis M.↗
DOE OSTI2023

Assessing the Impact of Mass Production on Microreactor Costs

Microreactors have attracted significant attention and investment. By virtue of their smaller size (typically less than ~20 MWe), they are expected to be significantly easier to build, demonstrate, and deploy than larger reactors. This has led to several U.S. companies pursuing active demonstration efforts with a wide variety of designs under development. For example, the Ultra Safe Nuclear Corporation (USNC), has recently announced they are planning to build a microreactor assembly plant in Alabama. The cost reduction of the microreactors via factory fabrication and mass production is expected to be the primary driver to the economic competitiveness of microreactors. While several entities are focused on first-of-a-kind demonstration of the technology, it is important to provide insights on longer-term considerations for mass production. The evaluation shown here was conducted primarily in collaboration with Munro & Associates Inc. The findings of this microreactor factory fabrication and mass production study were recently published in. In this paper, we start by summarizing the findings of this study. Next, we apply these findings to quantify the cost reduction of a heat pipe-cooled fast reactor (as an example of microreactors).

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2026

Drive Cycles, Battery Pack Scaling, and Usage Considerations for Long-Haul and Regional-Haul Electric Trucks

Electrifying Class-8 heavy-duty trucks presents a promising opportunity to enhance energy efficiency and reduce freight transport costs. Battery electric trucks (BETs), once considered niche, are gaining traction due to advancements in battery technology and cost reductions. However, accurately predicting battery lifespan under realistic usage conditions remains a key challenge. Understanding battery failure mechanisms and their links to design, operation, and management is essential for developers and fleet operators. This study introduces a method to develop simplified, lab-testable dynamic stress test (DST) cycles for regional and long-haul Class-8 BETs, derived from real-world diesel truck usage. These DSTs enable benchmarking of battery technologies, identification of aging stressors, and optimization of battery design, life, and cost. The approach supports evaluation of key metrics such as levelized cost of driving and total cost of ownership, aiding fair comparisons and adoption decisions. We also propose feasible battery pack sizes that meet current driving demands with strategic charging, and a method to scale pack-level DSTs to cell-level cycles for lab-based testing. These tools facilitate tradeoff analysis across battery chemistries, pack sizing, and charging strategies, while offering means to get insights into battery aging under realistic conditions-ultimately supporting informed BET deployment decisions.

25 ENERGY STORAGE↗
NASA NTRS2010

Cost Optimization and Technology Enablement COTSAT-1

Cost Optimized Test of Spacecraft Avionics and Technologies (COTSAT-1) is an ongoing spacecraft research and development project at NASA Ames Research Center (ARC). The space industry was a hot bed of innovation and development at its birth. Many new technologies were developed for and first demonstrated in space. In the recent past this trend has reversed with most of the new technology funding and research being driven by the private industry. Most of the recent advances in spaceflight hardware have come from the cell phone industry with a lag of about 10 to 15 years from lab demonstration to in space usage. NASA has started a project designed to address this problem. The prototype spacecraft known as Cost Optimized Test of Spacecraft Avionics and Technologies (COTSAT-1) and CheapSat work to reduce these issues. This paper highlights the approach taken by NASA Ames Research center to achieve significant subsystem cost reductions. The COSTAT-1 research system design incorporates use of COTS (Commercial Off The Shelf), MOTS (Modified Off The Shelf), and GOTS (Government Off The Shelf) hardware for a remote sensing spacecraft. The COTSAT-1 team demonstrated building a fully functional spacecraft for $500K parts and $2.0M labor. The COTSAT-1 system, including a selected science payload, is described within this paper. Many of the advancements identified in the process of cost reduction can be attributed to the use of a one-atmosphere pressurized structure to house the spacecraft components. By using COTS hardware, the spacecraft program can utilize investments already made by commercial vendors. This ambitious project development philosophy/cycle has yielded the COTSAT-1 flight hardware. This paper highlights the advancements of the COTSAT-1 spacecraft leading to the delivery of the current flight hardware that is now located at NASA Ames Research Center. This paper also addresses the plans for COTSAT-2.

Spremo, Stevan↗
NASA NTRS2016

Manufacturing Process Developments for Regeneratively-Cooled Channel Wall Rocket Nozzles

Regeneratively cooled channel wall nozzles incorporate a series of integral coolant channels to contain the coolant to maintain adequate wall temperatures and expand hot gas providing engine thrust and specific impulse. NASA has been evaluating manufacturing techniques targeting large scale channel wall nozzles to support affordability of current and future liquid rocket engine nozzles and thrust chamber assemblies. The development of these large scale manufacturing techniques focus on the liner formation, channel slotting with advanced abrasive water-jet milling techniques and closeout of the coolant channels to replace or augment other cost reduction techniques being evaluated for nozzles. NASA is developing a series of channel closeout techniques including large scale additive manufacturing laser deposition and explosively bonded closeouts. A series of subscale nozzles were completed evaluating these processes. Fabrication of mechanical test and metallography samples, in addition to subscale hardware has focused on Inconel 625, 300 series stainless, aluminum alloys as well as other candidate materials. Evaluations of these techniques are demonstrating potential for significant cost reductions for large scale nozzles and chambers. Hot fire testing is planned using these techniques in the future.

Gradl, Paul↗
DOE OSTI2026

Advanced Manufacturing of Cathode Materials for Lithium-ion Batteries

Original objectives (per the Statement of Project Objectives) centered on developing and translating a continuous pilot process for cathode materials production while targeting (i) a 29% manufacturing cost reduction, (ii) an 82% energy consumption reduction for cathode production, and (iii) a doubling of manufacturing productivity. Planned validation included characterization at appropriate analytical facilities and electrochemical performance evaluation progressing from half-cells to pouch-cell formats, with a pathway to kilogram-scale production of finished cathode materials for representative testing. Scope evolution: During execution, the project team identified that the surfactant-enabled chemistry offered high selectivity for lithium precipitation from brine sources. A formal scope revision shifted the final project year from cathode manufacturing development to direct lithium extraction/lithium recovery, while maintaining the overarching intent of cost reduction and process simplification relevant to the battery supply chain.

25 ENERGY STORAGE↗
DOE OSTI2023

Observations and Lessons Learned From Installing Residential Roofing-Integrated Photovoltaics

Building-sited solar photovoltaics (PV) could play a key role in decarbonizing the building sector either through racked and mounted PV or through Building-integrated PV (BIPV). BIPV is installed into the building envelope itself, with solar cells and/or modules forming the outer layer of a building structure, thus transforming a single-purpose structure into one that serves the dual purposes of the building envelope and electricity. BIPV can be applied to building roofs, facades, awnings, pergolas, windows, skylights, balustrades, and other external surfaces. Given BIPV products vary widely, the focus of this research is residential roofing integrated PV (RIPV), where solar is incorporated into or otherwise replaces the roofing material. Previous research suggests that residential RIPV could reduce customer acquisition, labor, supply chain, and equipment costs. These products have yet to realize these cost savings and deployment remains significantly less than conventional rooftop PV as a relative share of the addressable market in the US. One potential barrier to broader residential roofing integrated PV deployment may be higher costs relative to conventional rooftop PV, primarily because the design and installation of these products is still evolving. Here, we explore residential RIPV cost-reduction opportunities by analyzing installation processes. Our study documents residential RIPV installations at 2 reroofing sites and the equivalent of 9 new construction sites in California through a methodology known as time and motion study. We also conducted interviews with subject-matter experts to identify barriers and solutions to maximize these products' market penetration. Our time and motion study breaks the RIPV installation process into four steps: 1) staging, unloading, and roof preparation; 2) fire resistant underlayment(s) (synthetic material laid between roof shingles and roof deck); 3) flashings and PV installation; and 4) wiring and monitoring. We measure the time required for each step in terms of worker-hours, representing an hour of labor from a single worker. We further normalize process time by dividing worker-hours by kilowatt (kW) of system capacity. The most time-intensive step was flashings and PV installation, taking around 2.4 worker-hours per kW on average and accounting for around 60% of the process time for an average installation. The total installation process took on average about 6.4 and 3.5 worker-hours per kW at the reroofing sites and new construction sites, respectively. For comparison, a previous time and motion study documented a time of 6.9 worker-hours per kW for conventional rooftop PV. The shorter RIPV installation times are consistent with previous studies suggesting that RIPV could be installed faster than conventional rooftop PV. The time and motion results and feedback from interviewees provide insights into potential residential RIPV cost reduction opportunities. Several interviewees suggested that these products would be more efficient if PV installation was more fully integrated into the roofing/construction industries, which currently use separate supply chains and skillsets. Further integration could reduce supply chain delays and labor force redundancies. Future research could explore specific ways to integrate these industries to help realize the cost savings potential of RIPV.

14 SOLAR ENERGY↗
DOE OSTI2026

Diesel Fuel Consumption in Prominent U.S. Open-Pit Mines: Site-Level Estimates

This report presents a comprehensive framework for estimating diesel fuel consumption and prices at open-pit mines in the United States. The framework includes transparent methods for calculating site-level diesel energy use when direct reporting is unavailable, and a structured confidence evaluation for each method. The framework is demonstrated to estimate current diesel consumption at 21 open-pit mines in the United States. Initial findings support ongoing efforts to strengthen the competitiveness and security of the U.S. industrial base by supporting data-driven supply chain analysis and decision-making, improved transparency in mining sector energy use, and targeted deployment of energy innovation and cost-reduction strategies. Future updates to the dataset—coupled with expanded data transparency and method validation—will help ensure that the findings remain relevant as the sector continues to evolve.

02 PETROLEUM↗
NASA NTRS1999

A Study of Mars Dust Environment Simulation at NASA Johnson Space Center Energy Systems Test Area Resource Conversion Test Facility

The dust environment on Mars is planned to be simulated in a 20 foot thermal-vacuum chamber at the Johnson Space Center, Energy Systems Test Area Resource Conversion Test Facility in Houston, Texas. This vacuum chamber will be used to perform tests and study the interactions between the dust in Martian air and ISPP hardware. This project is to research, theorize, quantify, and document the Mars dust/wind environment needed for the 20 foot simulation chamber. This simulation work is to support the safety, endurance, and cost reduction of the hardware for the future missions. The Martian dust environment conditions is discussed. Two issues of Martian dust, (1) Dust Contamination related hazards, and (2) Dust Charging caused electrical hazards, are of our interest. The different methods of dust particles measurement are given. The design trade off and feasibility were studied. A glass bell jar system is used to evaluate various concepts for the Mars dust/wind environment simulation. It was observed that the external dust source injection is the best method to introduce the dust into the simulation system. The dust concentration of 30 Mg/M3 should be employed for preparing for the worst possible Martian atmosphere condition in the future. Two approaches thermal-panel shroud for the hardware conditioning are discussed. It is suggested the wind tunnel approach be used to study the dust charging characteristics then to be apply to the close-system cyclone approach. For the operation cost reduction purpose, a dehumidified ambient air could be used to replace the expensive CO2 mixture for some tests.

Chen, Yuan-Liang Albert↗
DOE OSTI2022

Lower Temperature Annealing of Vapor Diffused Nb₃Sn for Accelerator Cavities

Nb₃Sn is a next-generation superconducting material for the accelerator cavities with higher critical temperature and superheating field, both twice compared to Nb. It promises superior performance and higher operating temperature than Nb, resulting in significant cost reduction. So far, the Sn vapor diffusion method is the most preferred and successful technique to coat niobium cavities with Nb₃Sn. Although several post-coating techniques (chemical, electrochemical, mechanical) have been explored to improve the surface quality of the coated surface, an effective process has yet to be found. Since there are only a few studies on the post-coating heat treatment at lower temperatures, we annealed Nb₃Sn-coated samples at 800 C - 1000 C to study the effect of heat treatments on surface properties, primarily aimed at removing surface Sn residues. This paper discusses the systematic surface analysis of coated samples after annealing at temperatures between 850 C and 950 C.

43 PARTICLE ACCELERATORS↗
DOE OSTI2020

HAZARD ANALYSIS OF DIGITAL ENGINEERED SAFETY FEATURES ACTUATION SYSTEM IN ADVANCED NUCLEAR POWER PLANTS USING A REDUNDANCY-GUIDED APPROACH

Replacing the existing aging analog instrumentation and control (I&C) systems with modern safety control and protection digital technology offers one of the foremost means of performance improvements and cost reductions for the existing nuclear power plants (NPPs). However, the qualification of digital I&C systems remains a challenge, especially considering the issue of software common-cause failures (CCFs), which are difficult to address. With the application and upgrades of advanced digital I&C systems, software CCFs have become a potential threat to plant safety because most redundant designs use similar digital platforms or software in the operating and application systems. With complex designs of multilayer redundancy to meet the single-failure criterion, digital I&C safety systems (e.g., engineered safety-features actuation system [ESFAS]) are of a particular concern in the U.S. Nuclear Regulatory Commission (NRC) licensing procedures. This paper applies a modularized approach to conduct redundancy-guided systems-theoretic hazard analysis for an advanced digital ESFAS with multilevel redundancy designs. Systematic methods and risk-informed tools are incorporated to address both hardware and software CCFs, which provide guidance to eliminate the triggers of potential single points of failure in the design of digital safety systems in advanced plant designs.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2021

Low-Cost Aero Technology Demonstrations

The main focus of this work was to demonstrate the use of polymeric additive manufacturing (AM) to create tooling for both preforming and consolidation. Polymeric tooling was utilized where both modest and higher pressures are used for part consolidation. The key focus for the AM tooling development was for fabrication of complex structures such as ducting, C-channel stiffened skins, and airfoils where conventional male tooling would typically be trapped in the cured part. The AM tooling was evaluated for use as a tool master used to fabricate and re-shape deformable/re-formable mandrels based on SpinTech’s shape memory composite technology known as Smart Tooling. The AM tooling was also evaluated for use as a mold for composite infusion and consolidation. Key performance parameters were tracked for project schedule completion with each step comprising of “art to part” cycle time, cost, and model fidelity for dimensions, performance, and cost. The primary focus of this demonstration was to determine if a 50% cost reduction was achievable, for each AM tooling-set, as compared to conventional processes. UDRI leveraged project partner SpinTech, who manufactures tools and parts in these categories and thus provided a baseline regarding current best practices and provided valuable feedback during the entirety of this demonstration. This demonstration primarily focused on the use of AM tooling for fabrication of three composite component structures which are typically utilized in aircraft and comprise salient geometric features of broad interest. These components are often tooling intensive and have features requiring extraction of male tools which are usually trapped by the geometry. The three structures selected by the team included: 1) A one-piece airfoil shell comprised of compound contours where male tooling would be trapped unless the part were manufactured in two halves as is typically the case. 2) A one-piece duct used for air handling, comprised of compound contours where male tooling would be trapped unless the part were manufactured in two halves, or a washout mandrel were to be used. 3) A co-cured C-channel stiffened skin where typically C-channels would be individually manufactured and then bonded to a cured skin. The demonstration was comprised of three main tasks: • Task 1: AM Tool Feasibility Study – ensure the AM tooling meets the performance requirements as specified by SpinTech to match baseline performance. • Task 2: Complex Tool Demonstration – Fabricate tooling, preforms, and parts representative of an airfoil and duct. • Task 3: Large Aerostructure Fabrication Demonstration – Fabricate tooling, preforms, and part representative of a C-channel stiffened skin. With the conclusion of this project, a decision tree was developed to determine the key considerations necessary to determine if use of AM tooling for the three selected structures was able to attain the same quality as historically achieved on metallic tooling, while providing a significant cost reduction.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Self-consumption for energy communities in Spain: A regional analysis under the new legal framework

European climate polices acknowledge the role that energy communities can play in the energy transition. Self-consumption installations shared among those living in the same building are a good example of such energy communities. In this work, a regional analysis of optimal self-consumption installations under the new legal framework recently passed in Spain is performed. Results show that the optimal sizing of the installation leads to economic savings for self-consumers in all the territory, for both options with and without remuneration for energy surplus. A sensitivity analysis on technology costs revealed that batteries still require noticeably cost reductions to be cost-effective in a behind the meter self-consumption environment. In addition, solar compensation mechanisms make batteries less attractive in a scenario of low PV costs, since feeding PV surplus into the grid, yet less efficient, becomes more cost-effective. Furthermore, an improvement for the energy surplus remuneration policy in the context of the current legislation was proposed and analysed. It consists in the inclusion of the economic value of the avoided power losses in the remuneration.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2022

Coal to Carbon Fiber – A Novel Supercritical CO 2 Solvated Process

This project aims to demonstrate, independently, the three primary processes necessary to produce carbon fiber from coal feedstock material and assess the potential for those independent processes to integrate into a single, continuous process in order to provide significant cost reductions in the most costly steps of carbon fiber processing. The specific objective of the present research is to assess the technical feasibility for generation of quality carbon fiber pre-cursor materials from coal using a supercritical carbon dioxide (sCO 2 ) solvation process.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2024

Scaling Up: Demonstrating Risk Reduction and Cost Compression for Commercial Heat Pump Water Heaters - CRADA 625 (Abstract)

Commercial heat pump water heater (CHPWH) systems significantly decarbonize the commercial and multifamily sectors by eliminating the reliance on gas-fired water heating. CHPWH systems are also well suited to include load shift controls that enable load-up and shed commands for supporting grid reliability and time-of-use pricing structure. However, they have not had wide adoption due to factors including price, complexity, and perceived risk. Although CHPWHs have been available in the US for decades, they have not made significant market gains in part because the systems have required significant and costly engineering design expertise and proved lackluster performance. Successful widespread market adoption requires a different approach; a shift from the current custom specialized expertise project design and installation to a repeatable approach that requires little specialized knowledge or expertise and can deliver persistent performance. Using this type of holistic systems approach requires effectively integrating four CHPWH system key components: primary air-to-water heat pumps; primary thermal storage tanks, a temperature maintenance system, and a control system which has capabilities to manage the primary heat pump cycles, any back-up, supplemental, or temperature maintenance heating, alarms, and grid connectivity allowing for demand response (DR), and/or load shifting. The project team has developed and will implement a suite of tools to support faster, less expensive, and more reliable field installations of CHPWH technology and with the resulting data used to further improve the tool set. These tools include: (1) A tool for optimizing system size and costs. (2) A tool that predicts annual energy use and overall system efficiency. (3) The Advanced Water Heater Specification (AWHS 8.0) defining the components of a full CHPWH system addressing performance requirements by climate zone. (4) The Qualified Products List: (QPL) of approved products that meet the specifications requirements. (5) Training materials including online on-demand modules, instructor-led training, and virtual interactive video tours of CHPWH installations in multifamily buildings. Demonstration site identification in low-income buildings in underserved communities is currently underway. Preliminarily, the team anticipates having three demonstrations in the Pacific Northwest and three in the Northeast for a total of six sites. After the demonstration sites are finalized, and M&V instrumentation installations are complete, the team will gather performance data and confirm whether the CHPWH systems perform as predicted and use the data to improve the existing tools.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
NASA NTRS1973

Payload design requirements analysis (study 2.2). Volume 1: Executive summary

Research was conducted to provide data on ways to effectively realize the projected cost reductions for payloads to be developed and operated in the shuttle era. Prior studies have indicated that the Shuttle concept of satellite operations will lead to a large reduction in overall payload cost. This study provides the data and insight into the methods of accomplishing these economic benefits. The study examined only payloads that will be launched on the shuttle/tug/sortie lab combinations. These payloads are of four types: (1) expendable; (2) ground refurbishable; (3) on-orbit maintainable; and (4) sortie. The expendable payloads are intended specifically for the shuttle/tug and not for expendable launch vehicles. Economic comparisons were made only between these four types of shuttle payloads and not between these payloads and current expendable launch vehicle payloads.

Shiokari, T.↗
NASA NTRS1975

NASA Office of Aeronautics and Space Technology Summer Workshop. Volume 1: Data processing and transfer panel

The data processing and transfer technology areas that need to be developed and that could benefit from space flight experiments are identified. Factors considered include: user requirements, concepts in 'Outlook for Space', and cost reduction. Major program thrusts formulated are an increase in end-to-end information handling and a reduction in life cycle costs.

Source record↗
NASA NTRS1984

Photovoltaic central-station power conditioner subsystems

The potential of applying new advanced circuit topologies and semiconductors with improved switching characteristics to the design and development of central-station power conditioning subsystems is assessed. State-of-the-art large power conditioners suitable for photovoltaic central-station application are reviewed. Advanced topology power conditioning subsystems, when compared to available production hardware, promise improved performance, significant cost reduction, and lower cost-to-efficiency ratios.

Krauthamer, S.↗