Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “3D PRINTING”

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 217 records · Page 12
All sourcesNASA NTRSDOE OSTI
NASA NTRS2017

Abstract - Belbas, Nicholas (EC2)

Originally, I was brought into the Design and Analysis Branch in the Crew and Thermal Systems to work on administrative tasks like archiving and scheduling. However, I ended up splitting my time between secretarial tasks and a technical project. My technical project was originally meant to be a wireless sensor package for the 20ft Spacecraft Thermal Vacuum Chamber in the B7 High Bay. I would be using a miniature wifi development board and a temperature/humidity sensor along with custom 3D modeling to accomplish this. However, after some discussion with my technical mentor, the plan was changed to a mobile autonomous self-charging sensor platform. A mobile platform will allow the sensors to be moved around without depressurizing the chamber. Also, the self-charging aspect of the package allows for almost unlimited time in the chamber. If the on-board battery runs low, the robot can easily be driven to its charging dock and continue to transmit while charging. The driving base is based around a Raspberry Pi 3 board with a 12C PMW DC Motor controller and a PWM controller driving two small gear motors. The sensor transmitter itself is a RHT03 temperature and humidity sensor and Cozir CO2 sensor connected to an ESP8266 Huzzah board. The power distribution system utilizes a pair of 3.7v 3600mah lipo batteries wired to Powerboost 500 boards. Also, the self-charging mechanism utilizes two 12v-max inductive charging coils wired into the same Powerboost boards as the battery. The Raspberry pi is running Python 3.3 for the driving base and Javascript MJPEG library for transmitting live video from the onboard camera. The sensor package is running Arduino-based C++ and the program capturing the data is running PyqtGraph Python and HTML. The shell of the robot itself is a 3D printed case that will (work in progress) snap together. The photo to the left shows the two halves separated from each other. The black shell contains the power distribution boards and connectors while the white shell contains the driving base and data systems.

Belbas, Nicholas↗
NASA NTRS2017

Work Term Assignment Spring 2017

My tour in the Engineering Robotics directorate exceeded my expectations. I learned lessons about Creo, manufacturing and assembly, collaboration, and troubleshooting. During my first tour, last spring, I used Creo on a smaller project, but had limited experience with it before starting in the Dynamic Systems Test branch this spring. I gained valuable experience learning assembly design, sheet metal design and designing with intent for manufacturing and assembly. These skills came from working both on the hatch and the floor. I also learned to understand the intent of other designers on models I worked with. While redesigning the floor, I was modifying an existing part and worked to understand what the previous designer had done to make it fit with the new model. Through working with the machine shop and in the mock-up, I learned much more about manufacturing and assembly. I used a Dremel, rivet gun, belt sander, and countersink for the first time. Through taking multiple safety training for different machine shops, I learned new machine shop safety skills specific to each one. This semester also gave me new collaborative opportunities. I collaborated with engineers within my branch as well as with Human Factors and the building 10 machine shop. This experience helped me learn how to design for functionality and assembly, not only for what would be easiest in my designs. In addition to these experiences, I learned many lessons in troubleshooting. I was the first person in my office to use a Windows 10 computer. This caused unexpected issues with NASA services and programs, such as the Digital Data Management Server (DDMS). Because of this, I gained experience finding solutions to lockout and freeze issues as well as Creo specific settings. These will be useful skills to have in the future and will be implemented in future rotations. This co-op tour has motivated me more to finish my degree and pursue my academic goals. I intend to take a machining Career Gateway Elective in the Fall to improve my skills in building as well as designing with manufacturing intent. I am also inspired to take more mechatronics CGE courses before I graduate to learn more about the crossover between mechanical and electrical engineering. This semester, I worked on multiple projects and had the opportunity to learn from engineers of different disciplines. I became proficient in Creo 2.0, a program I had not used significantly before. I finished modifying the hatch for 3D print and made sizeable modifications to the nose floor support design. I also gained hands-on experience that will be useful in my engineering career in the future. I would consider all of these major achievements from this spring semester. Lastly, I learned to ask more questions and to search for the right people to find answers which I know will be a valuable skill in the future. This summer, I will be completing my last rotation in the Flight Operations Directorate at Ellington Air Field. After this last tour, I will be returning to school for the Fall, Spring and Summer. I will graduate in August of 2018. I am looking forward to learning more about the different jobs available to engineers. This division works directly with many different types of aircrafts and I am excited to learn more about this focus of engineering. The Aircraft Operations Division values team work greatly and I intend to improve my interpersonal skills by working with them this summer.

Sico, Mallory↗
NASA NTRS2017

Space Resource Technologies

PowerPoint presentation for the Society of Women Engineers presented by Rachel Cox to give an overview of NASA Swamp Works, the kind of work we do, explain what ISRU (living off the land in space) is about, and highlight several projects. Projects include RASSOR the space mining robot, Resource Prospector, ALTIP, Marco Polo, and regolith construction, including heat shields and 3D printing. Content is similar to what is presented on Swamp Works tours (we get about 2,000 visitors a year) and is high level and conceptual in nature (no engineering specsdimensions.)

Cox, Rachel↗
NASA NTRS2017

Educational Projects in Unmanned Aerial Systems at the NASA Ames Research Center

Unmanned aerial systems (UAS), autonomy and robotics technology have been fertile ground for developing a wide variety of interdisciplinary student learning opportunities. In this talk, several projects will be described that leverage small fixed-wing UAS that have been modified to carry science payloads. These aircraft provide a unique hands-on experience for a wide range of students from college juniors to graduate students pursuing degrees in electrical engineering, aeronautical engineering, mechanical engineering, applied mathematics, physics, structural engineering and other majors. By combining rapid prototyping, design reuse and open-source philosophies, a sustainable educational program has been organized structured as full-time internships during the summer, part-time internships during the school year, short details for military cadets, and paid positions. As part of this program, every summer one or more UAS is developed from concept through design, build and test phases using the tools and facilities at the NASA Ames Research Center, ultimately obtaining statements of airworthiness and flight release from the Agency before test flights are performed. In 2016 and 2017 student projects focused on the theme of 3D printed modular airframes that may be optimized for a given mission and payload. Now in its fifth year this program has served over 35 students, and has provided a rich learning experience as they learn to rapidly develop new aircraft concepts in a highly regulated environment, on systems that will support principal investigators at university, NASA, and other US federal agencies.

UA↗
NASA NTRS2016

NH11B-1726: FrankenRaven: A New Platform for Remote Sensing

Small, modular aircraft are an emerging technology with a goal to maximize flexibility and enable multi-mission support. This reports the progress of an unmanned aerial system (UAS) project conducted at the NASA Ames Research Center (ARC) in 2016. This interdisciplinary effort builds upon the success of the 2014 FrankenEye project to apply rapid prototyping techniques to UAS, to develop a variety of platforms to host remote sensing instruments. In 2016, ARC received AeroVironment RQ-11A and RQ-11B Raven UAS from the US Department of the Interior, Office of Aviation Services. These aircraft have electric propulsion, a wingspan of roughly 1.3m, and have demonstrated reliability in challenging environments. The Raven airframe is an ideal foundation to construct more complex aircraft, and student interns using 3D printing were able to graft multiple Raven wings and fuselages into FrankenRaven aircraft. Aeronautical analysis shows that the new configuration has enhanced flight time, payload capacity, and distance compared to the original Raven. The FrankenRaven avionics architecture replaces the mil-spec avionics with COTS technology based upon the 3DR Pixhawk PX4 autopilot with a safety multiplexer for failsafe handoff to 2.4 GHz RC control and 915 MHz telemetry. This project demonstrates how design reuse, rapid prototyping, and modular subcomponents can be leveraged into flexible airborne platforms that can host a variety of remote sensing payloads and even multiple payloads. Modularity advances a new paradigm: mass-customization of aircraft around given payload(s). Multi-fuselage designs are currently under development to host a wide variety of payloads including a zenith-pointing spectrometer, a magnetometer, a multi-spectral camera, and a RGB camera. After airworthiness certification, flight readiness review, and test flights are performed at Crows Landing airfield in central California, field data will be taken at Kilauea volcano in Hawaii and other locations.

remote sensing↗
NASA NTRS2017

A UAV-Based Fog Collector Design for Fine-Scale Aerobiological Sampling

Airborne microbes are found throughout the troposphere and into the stratosphere. Knowing how the activity of airborne microorganisms can alter water, carbon, and other geochemical cycles is vital to a full understanding of local and global ecosystems. Just as on the land or in the ocean, atmospheric regions vary in habitability; the underlying geochemical, climatic, and ecological dynamics must be characterized at different scales to be effectively modeled. Most aerobiological studies have focused on a high level: 'How high are airborne microbes found?' and 'How far can they travel?' Most fog and cloud water studies collect from stationary ground stations (point) or along flight transects (1D). To complement and provide context for this data, we have designed a UAV-based modified fog and cloud water collector to retrieve 4D-resolved samples for biological and chemical analysis.Our design uses a passive impacting collector hanging from a rigid rod suspended between two multi-rotor UAVs. The suspension design reduces the effect of turbulence and potential for contamination from the UAV downwash. The UAVs are currently modeled in a leader-follower configuration, taking advantage of recent advances in modular UAVs, UAV swarming, and flight planning.The collector itself is a hydrophobic mesh. Materials including Tyvek, PTFE, nylon, and polypropylene monofilament fabricated via laser cutting, CNC knife, or 3D printing were characterized for droplet collection efficiency using a benchtop atomizer and particle counter. Because the meshes can be easily and inexpensively fabricated, a set can be pre-sterilized and brought to the field for 'hot swapping' to decrease cross-contamination between flight sessions or use as negative controls.An onboard sensor and logging system records the time and location of each sample; when combined with flight tracking data, the samples can be resolved into a 4D volumetric map of the fog bank. Collected samples can be returned to the lab for a variety of analyses. Based on a review of existing flight studies, we have identified ion chromatography, metagenomic sequencing, cell staining and quantification, and ATP quantification as high-priority assays for implementation. Support for specific toxicology assays, such as methylmercury quantification, is also planned.

Design↗
NASA NTRS2018

Overview of Additive Manufacturing Initiatives at NASA Marshall Space Flight Center

NASA's In Space Manufacturing Initiative (ISM) includes: The case for ISM - why; ISM path to exploration - results from the 3D Printing In Zero-G Technology Demonstration - ISM challenges; In space Robotic Manufacturing and Assembly (IRMA); Additive construction. Additively Manufacturing (AM) development for liquid rocket engine space flight hardware. MSFC standard and specification for additively manufactured space flight hardware. Summary.

Clinton, R. G., Jr.↗
NASA NTRS2018

Interplanetary Supply Chain Risk Management

Emphasis on KSC ground processing operations, reduced spares up-mass lift requirements and campaign-level flexible path perspective for space systems support as Regolith-based ISM is achieved by; Network modeling for sequencing space logistics and in-space logistics nodal positioning to include feedstock. Economic modeling to assess ISM 3D printing adaption and supply chain risk.

Galluzzi, Michael C.↗
NASA NTRS2018

Hybrid Additive Manufacturing Deposition and Selective Laser Melting Techniques Applied to Copper-Alloy Liquid Rocket Engine Combustion Chambers

Virgin Orbit and the NASA Marshall Space Flight Center have partnered to fabricate a small, multi-metallic, regeneratively cooled thrust chamber by leveraging the strengths of two different types of additive manufacturing: Direct Metal Laser Sintering (DMLS) for the copper alloy liner and blown powder Directed Energy Deposition (DED) for the Inconel structural jacket. The DED is being developed using Virgin Orbit's DMG Mori Seiki hybrid additive/subtractive machining center to further enable unique processing and further cost savings. The materials chosen are preferred for high performance thrust chamber applications, representing a significant advancement from the compromises typically made in the production of metal 3D printed thrust chambers for rocket engines. The 1.2K-lbf thrust article is a 16" tall, 3" diameter design modified for this effort to be regeneratively cooled with water and hot fired using a RP-1/LOX pintle-style development injector from Virgin Orbit's NewtonFour upper stage engine. The thrust chamber was tested at Virgin Orbit's Necker test site in Mojave, California. Results from this test campaign are reported in addition to information characterizing the liner, jacket, and bimetallic diffusion layer materials. This paper will also highlight some of the future bimetallic thrust chamber developments that MSFC and Virgin Orbit will complete under a recently awarded NASA contract.

Zagorski, Kevin↗
NASA NTRS2018

Building a Plastics Fabrication Laboratory on the ISS: FabLab, MANTIS, Refabricator, CRISSP, ERASMUS, and MAMBA

The objective of NASA's In Space Manufacturing program is to develop manufacturing technologies and processes necessary to provide "on-demand, sustainable operations for exploration missions." Using the ISS as a test bed, in 2014, NASA installed and successfully tested a 3D printer for in-space operations, demonstrating the 3D printing process as well as sending digital files for printing from earth to the printer. The success of this technology demonstration has shown that on-orbit manufacturing technologies can be used to limit the earth reliance for cis-lunar missions. Because of this success, numerous opportunities have been provided by NASA to further in-space manufacturing by focusing on the development of highly autonomous manufacturing systems, recycling technologies, and robotics with the ultimate goal of building a fabrication laboratory now within reach. From technologies developed for ISS activities and demonstration missions, Tethers Unlimited, Inc. (TUI) is building a Plastics Manufacturing Laboratory capable of fabricating parts on-demand and as-needed while recycling waste plastics with minimal human interaction required. Parts will be manufactured through additive manufacturing. Precision machining will ensure manufactured parts are in tolerance with the end-use requirements. Recycling waste plastics will enable both waste from the crew and waste from processing to be re-processed into something new. In addition, these manufacturing and recycling technologies are supported by part verification/validation technique and robotic servicing, minimizing human interaction with the system and eventually enabling unmanned off-world manufacturing.

Muhlbauer, Rachel↗
NASA NTRS2018

Additively Manufactured Oxidizer Turbopump

Additive Manufacturing, or 3D printing, is a key technology for enhancing rocket engine designs and making them more affordable for future exploration missions. The Oxidzer Turbopump (OTP) offers the ability to demonstrate additively manufactured rotating, vaned, and critical pressure vessel components in relevant oxygen turbopump environments. The additively manufactured components of the OTP include the main housings, impeller, and turbine components. A key technology development goal is to understand the benefits and limitations of additive manufacturing as it applies to the complex geometries needed for a rocket engine turbopump.

Manufacturing↗
NASA NTRS2018

NASA Additive Manufacturing Initiatives for Deep Space Human Exploration

Additive Manufacturing (AM) is being infused into aerospace industries at an accelerated pace. Reasons for this rapid adoption include: (1) Innovation Capability e.g. design features such as topology optimization, integrated fluid passages, and mesh structures; (2) Rapid Development and Optimization - ability to quickly iterate the design, development, and test cycle; (3) Affordability - reductions in part counts, cost, and schedule. NASA's Marshall Space Flight Center (MSFC) has taken a leadership role in application of AM technologies for deep space human exploration, leading the Agency's In Space Manufacturing (ISM) initiative and the application of AM for a broad variety of space propulsion systems. MSFC has championed the development of ISM capabilities since our first reduced-gravity aircraft experiment flew in 1999. Partnering with Made In Space, MSFC placed the first 3D Printer on ISS in 2014 and the second generation printer, the Additive Manufacturing Facility, in 2016. The next ISS technology demonstration will be the Refabricator, a recycler/basic printer scheduled to launch in late Fall 2018. Ground-based development is progressing in common use materials, metals 3D printing, printed electronics, and the new cornerstone of ISM, the FabLab. The latest developments in each area will be described. An overview of NASA's In Space Robotic Manufacturing and Assembly (IRMA) ground-based risk reduction projects will also be presented. MSFC has aggressively incorporated AM capabilities for design and development of space propulsion components. The capabilities have been rapidly matured and extensively exercised to produce and hot-fire test the Additive Manufacturing Demonstrator Engine, an in-space class prototype engine. This experience base has been extended to support Aerojet Rocketdyne in the application of AM to the RS-25, the Space Launch System Core Stage engine, and to small propulsion systems and thrusters for small satellites and cubesats. The latest developments will be described. In responding to a request from NASA's Commercial Crew Program for a consistent methodology for evaluation of AM processes and parts, MSFC began development of a draft standard for AM space flight hardware in late 2014. The draft was broadly disseminated for comments in mid-2015, and subsequently revised into two documents, a standard and a specification for AM space flight hardware, which were formally released by MSFC in October 2017. An overview of the key elements of these documents will be presented.

Clinton, Raymond↗
NASA NTRS2018

NASA's Space Launch System and Deep Space Opportunities for Smallsats

Overview of the agency’s plans for deep space exploration: NASA has a phased approach to successful human exploration of deep space; We began LEO (Low Earth Orbit), where we’ve lived aboard the ISS continuously for more than 17 years; What have we learned in those years that will help us put boots on the moon with eyes toward Mars? And also help us on Earth? - Advances in materials research - 3D printing in space - Engineered life support systems for sustained stays in space - Better understanding of the effects of microgravity on the human body - We deploy CubeSats from the ISS (International Space Station) - We’ve cooperate with international partners - We’ve opened transportation to LEO to commercial vehicles; Allowing commercial companies to take over LEO frees NASA to explore deep space - next step is back to the Moon; NASA will establish a lunar Gateway near the moon (near rectilinear halo orbit);The Gateway will be crew tended (30-90 day missions); Gateway will communicate with Earth and lunar surface; Will open new opportunities for robotic exploration of the moon, especially far side of the moon and poles; Prospecting for volatiles will be high on the list of priorities; SLS (Space Launch System)/Orion will participate in gateway assembly and operation; Will serve as a testbed for new technologies and inform future Mars missions; After learning how to live and work in deep space like we did in LEO, NASA will move on Mars missions; SLS’s capability to accommodate primary, co-manifested and secondary payloads (when available) is a key component in making this vision a reality.

Bookout, Paul S.↗
NASA NTRS2016

A UAV-Based Fog Collector Design for Fine-Scale Aerobiological Sampling

Airborne microbes are found throughout the troposphere and into the stratosphere. Knowing how the activity of airborne microorganisms can alter water, carbon, and other geochemical cycles is vital to a full understanding of local and global ecosystems. Just as on the land or in the ocean, atmospheric regions vary in habitability; the underlying geochemical, climatic, and ecological dynamics must be characterized at different scales to be effectively modeled. Most aerobiological studies have focused on a high level: 'How high are airborne microbes found?' and 'How far can they travel?' Most fog and cloud water studies collect from stationary ground stations (point) or along flight transects (1D). To complement and provide context for this data, we have designed a UAV-based modified fog and cloud water collector to retrieve 4D-resolved samples for biological and chemical analysis.Our design uses a passive impacting collector hanging from a rigid rod suspended between two multi-rotor UAVs (Unmanned Aerial Vehicles). The suspension design reduces the effect of turbulence and potential for contamination from the UAV downwash. The UAVs are currently modeled in a leader-follower configuration, taking advantage of recent advances in modular UAVs, UAV swarming, and flight planning.The collector itself is a hydrophobic mesh. Materials including Tyvek, PTFE, nylon, and polypropylene monofilament fabricated via laser cutting, CNC knife, or 3D printing were characterized for droplet collection efficiency using a benchtop atomizer and particle counter. Because the meshes can be easily and inexpensively fabricated, a set can be pre-sterilized and brought to the field for 'hot swapping' to decrease cross-contamination between flight sessions or use as negative controls.An onboard sensor and logging system records the time and location of each sample; when combined with flight tracking data, the samples can be resolved into a 4D volumetric map of the fog bank. Collected samples can be returned to the lab for a variety of analyses. Based on a review of existing flight studies, we have identified ion chromatography, metagenomic sequencing, cell staining and quantification, and ATP quantification as high-priority assays for implementation. Support for specific toxicology assays, such as methyl-mercury quantification, is also planned.

Design↗
NASA NTRS2018

High-precision Method for Cyclic Loading of Small-Animal Vertebrae to Assess Bone Quality

One potentially important bone quality characteristic is the response of bone to cyclic (repetitive) mechanical loading. In small animals, such as in rats and mice, cyclic loading experiments are particularly challenging to perform in a precise manner due to the small size of the bones and difficult-to-eliminate machine compliance. Addressing this issue, we developed a precise method for ex vivo cyclic compressive loading of isolated mouse vertebral bodies. The method has three key characteristics: 3D-printed support jigs for machining plano-parallel surfaces of the tiny vertebrae; pivotable loading platens to ensure uniform contact and loading of specimen surfaces; and specimen-specific micro-CT-based finite element analysis to measure stiffness to prescribe force levels that produce the same specified level of strain for all test specimens. To demonstrate utility, we measured fatigue life for three groups (n = 5-6 per group) of L5 vertebrae of C57BL/6J male mice, comparing our new method against two methods commonly used in the literature. We found reduced scatter of the mechanical behavior for this new method compared to the literature methods. In particular, for a controlled level of strain, the standard deviation of the measured fatigue life was up to 5-fold lower for the new method (F-ratio = 4.9; p < 0.01). The improved precision for this new method for biomechanical testing of small-animal vertebrae may help elucidate aspects of bone quality.

Bone quality↗
NASA NTRS2019

A NASA Supply Chain Beyond Low Earth Orbit: Explore Moon to Mars

Presentation will highlight the Space Shuttle Program Lessons Learned with a simulation of the complexity, volatility and multi-functional relationships of the supplier base followed by a review of a key element in the NASA KSC Supply Chain/Logistics Strategic Roadmap to include supply chain resiliency modeling as impacted by 3D Printing technology maturation and campaign-level network flow modeling for logistics nodal positioning of critical product needed to support space operations and In-Space Manufacturing beyond Low Earth Orbit.

Supply Chain Analytics↗
NASA NTRS2018

Aerodynamic and Structural Evaluation of an SMA Slat-Cove Filler Using Computational and Experimental Tools at Model Scale

Transport class aircraft produce a significant amount of airframe noise during approach and landing due to exposed geometric discontinuities that are hidden during cruise. The leading-edge slat is a primary contributor to this noise. In previous work, use of a slat-cove filler (SCF) has proven to reduce airframe noise by filling the cove aft of the slat, eliminating the circulation region within the cove. The goal of this work is to extend and improve upon past experimental and computational efforts on the evaluation of a scaled high-lift wing with a super elastic shape memory alloy (SMA) SCF. Recent turbulence measurements of the Texas A&M University 3ft-by-4ft wind tunnel allow for more accurate representation of the flow through the test section in computational fluid dynamics (CFD) analysis. The finite volume models used in CFD analysis are coupled to structural finite element models using a framework compatible with an SMA constitutive model and significant deformation, enabling fluid-structure interaction (FSI) analysis of the SCF. Both fully-deployed and retraction/deployment cases are considered. The displacement of the SCF on the experimental model is measured at various stages of retraction/deployment using a laser displacement sensor and digital image correlation system. Due to a lack of structural stiffness in the 3D-printed plastic slat during retraction and SCF stowage, a rigid steel slat is incorporated into the physical model and preliminary wind tunnel tests are conducted at multiple angles of attack in both retracted and deployed configurations.

Scholten, William↗
NASA NTRS2019

Investigation of Anti-Phase Asymmetric Quiet Rotor Technology

The future of urban air mobility has a well-known tall pole challenge in the form of community acceptance which largely comes from the noise. This paper presents a proposed anti-phase rotor technology that could reduce noise sources such as blade vortex interaction noise. The anti-phase rotor technology includes a rotor design with various anti-phase alternating trailing edge patterns and a rotor design with an asymmetric blade tip. Four small-scale anti-phase rotors are fabricated by 3D printing for acoustic measurements conducted in a low-speed open-circuit wind tunnel to assess the effectiveness of the proposed anti-phase rotor technology. Preliminary test results appear to be promising and indicate that the anti-phase rotor designs could be a practical means of reducing blade vortex interactions and noise. The four tested anti-phase rotor designs have peak acoustic performance depending on the RPM and thrust which suggests improved performance through design optimization could be achieved for specific mission requirements.

Cramer, Nicholas B.↗