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All sourcesNASA NTRSDOE OSTI
NASA NTRSDate not supplied

Technological Developments of NexGen Micro-Shutter Array (NGMSA) for the Future Habitable Worlds Observatory (HWO) Flagship Mission

We present the most up to date advancements in production, design, and performance of the NexGen Micro-Shutter Array (NGMSA) for Multi-object Spectroscopy (MOS), intended for the future Habitable Worlds Observatory (HWO) Flagship. A microshutter array functions as a programmable slit mask, to generate slits corresponding to sparsely distributed sources in the field of view of a telescope. In contrast to the magnetic/electrostatic microshutter arrays used in the James Webb Space Telescope (JWST), the NGMSA is fully operated by electrostatics, simplifying overall system. Our small pilot array proved its capability from FORTIS sounding rocket mission in 2019. As we are switching to a larger HWO flight size array process, we encounter multiple processing related issues. Also, there has been individual shutter level issue that impairs operation and performance. We will discuss those problems and strategies to overcome the challenges to achieve an on/off contrast of >1e5 with near 100% shutter operability.

Microshutter↗
NASA NTRS2017

NASA's In-Space Manufacturing Project: Materials and Manufacturing Process Development Update

The mission of NASA's In-Space Manufacturing (ISM) project is to identify, design, and implement on-demand, sustainable manufacturing solutions for fabrication, maintenance and repair during exploration missions. ISM has undertaken a phased strategy of incrementally increasing manufacturing capabilities to achieve this goal. The ISM project began with the development of the first 3D printer for the International Space Station. To date, the printer has completed two phases of flight operations. Results from phase I specimens indicated some differences in material properties between ground-processed and ISS-processed specimens, but results of follow-on analyses of these parts and a ground-based study with an equivalent printer strongly indicate that this variability is likely attributable to differences in manufacturing process settings between the ground and flight prints rather than microgravity effects on the fused deposition modeling (FDM) process. Analysis of phase II specimens from the 3D Printing in Zero G tech demo, which shed further light on the sources of material variability, will be presented. The ISM project has also developed a materials characterization plan for the Additive Manufacturing Facility, the follow-on commercial multimaterial 3D printing facility developed for ISS by Made in Space. This work will yield a suite of characteristic property values that can inform use of AMF by space system designers. Other project activities include development of an integrated 3D printer and recycler, known as the Refabricator, by Tethers Unlimited, which will be operational on ISS in 2018. The project also recently issued a broad area announcement for a multimaterial fabrication laboratory, which may include in-space manufacturing capabilities for metals, electronics, and polymeric materials, to be deployed on ISS in the 2022 timeframe.

Prater, Tracie↗
NASA NTRS2019

Laser Sintering of Thermoset Polyimide Composites

Selective Laser Sintering (SLS) is an additive manufacturing technique that builds 3D models layer by layer using a laser to selectively melt cross sections in powdered polymeric materials, following sequential slices of the CAD model. SLS generally uses thermoplastic polymeric powders, such as polyamides (i.e. Nylon), and the resultant 3D objects are often weaker in their strength compared to traditionally processed materials, due to the lack of polymer inter-chain connection in the z-direction. Our previous effort showed the challenges of printing a melt-processable RTM370 imide resin powder terminated with reactive 4-phenylethynylphthalic anhydride by LS, due to its inherently low viscosity of these oligomers. This paper presented the first successful 3D printing of high temperature carbon fiber filled thermoset polyimide composites, followed by post cure cycles to promote additional crosslinking for achieving higher temperature (Tg = 370 °C) capability. The processes to build tensile specimens and a component by LS, and the characterization of RTM370 imide resin by DSC and rheology as well as evaluation of the LS printed polyimide composite specimens by SEM and mechanical tests will be discussed.

Polyimide Composites↗
NASA NTRS2023

Reactive Additive Manufacturing for Fourth Industrial Revolution Exploration Systems (Ramfire) Aluminum 6061-Ram2 Nozzle Testing

The NASA Marshall Space Flight Center (MSFC) has applied various forms of metallic additive manufacturing (AM) in liquid rocket engine component design, development, and testing since 2010. These AM techniques reduce hardware cost, shorten fabrication schedules, increase reliability by reducing the number of joints, and improve hardware performance by allowing unconventional design. The RAMFIRE project, funded under Space Technology Mission Directorate (STMD) Game Changing Development (GCD) Program, has furthered the use of novel AM liquid rocket nozzles in collaboration with Elementum 3D. The project advanced novel large-scale AM aluminum material technology for significant weight savings in rocket engines and launch vehicles. Previously, aluminum alloys were difficult to weld and print using additive manufacturing. Elementum 3D’s patented Aluminum 6061-RAM2 alloy allows for aluminum alloys to be printed using various AM techniques and at various scales. The alloy can be leveraged for welding wire, showing drastic improvements in aluminum weldability. The RAMFIRE project focuses on five key areas: 1) Laser Powder Directed Energy Deposition (LP-DED) AL6061-RAM2 feedstock specification and verification, 2) LP-DED process development and validation, 3) LP-DED printed AL6061-RAM2 microstructural and mechanical property characterization, 4) Hot-fire test a 7k-lbf thrust class regeneratively cooled nozzle, 5) Print large scale regeneratively cooled nozzle. Hot-fire testing demonstrates potential of advanced space technologies to NASA and potential users by providing the relevant environments to advance TRL levels to the 5/6 range.

Al6061-RAM2↗
NASA NTRS2005

Feasibility Assessment for Pressure Casting of Ceramic-Aluminum Composites for NASA's Propulsion Applications

Feasibility assessment of pressure casting of ceramic-aluminum composites for NASA% propulsion applications is summarized. A combination of several demonstration projects to produce three unique components for liquid hydrogen-oxygen rocket engine% flanges, valves and turbo-pump housing are conducted. These components are made from boron carbide, silicon carbide and alumina powders fabricated into complex net shaped parts using dry green powder compaction, slip casting or a novel 3D ink-jet printing process, followed by sintering to produce performs that can be pressure cast by infiltration with molten aluminum. I n addition, joining techniques are also explored to insure that these components can be assembled into a structure without degrading their highly tailored properties. The feasibility assessment was made to determine if these new materials could provide a significant weight savings, thereby reducing vehicle launch costs, while being durable materials to increase safety and performance for propulsion system.

Lee, Jonathan A.↗
NASA NTRS2018

NASA Fluid Lensing & MiDAR - Next-Generation Remote Sensing Technologies for Aquatic Remote Sensing

Piti's Tepungan Bay and Tumon Bay, two of five marine preserves in Guam, have not been mapped to a level of detail sufficient to support proposed management strategies. This project addresses this gap by providing high resolution maps to promote sustainable, responsible use of the area while protecting natural resources. Dr. Chirayath, a research scientist at the NASA Ames Laboratory, developed a theoretical model and algorithm called 'Fluid Lensing'. Fluid lensing removes optical distortions caused by moving water, improving the clarity of the images taken of the corals below the surface. We will also be using MiDAR, a next-generation remote sensing instrument that provides real-time multispectral video using an array of LED emitters coupled with NASA's FluidCam Imaging System, which may assist Guam's coral reef response team in understanding the severity and magnitude of coral bleaching events. This project will produce a 3D orthorectified model of the shallow water coral reef ecosystems in Tumon Bay and Piti marine preserves. These 3D models may be printed, creating a tactile diorama and increasing understanding of coral reefs among various audiences, including key decision makers. More importantly, the final data products can enable accurate and quantitative health assessment capabilities for coral reef ecosystems.

Aquatic↗
NASA NTRS2008

Innovative Applications of Laser Scanning and Rapid Prototype Printing to Rock Breakdown Experiments

We present the novel application of two technologies for use in rock breakdown experiments, i.e. close-range, ground-based 3D triangulation scanning and rapid prototype printing. These techniques aid analyses of form-process interactions across the range of scales relevant to breakdown (micron-m). This is achieved through (a) the creation of DEMs (which permit quantitative description and analysis of rock surface morphology and morphological change) and (b) the production of more realistically-shaped experimental blocks. We illustrate the use of these techniques, alongside appropriate data analysis routines, in experiments designed to investigate the persistence of fluvially-derived features in the face of subsequent wind abrasion and weathering. These techniques have a range of potential applications in experimental field and lab-based geomorphic studies beyond those specifically outlined here.

Bourke, Mary↗
NASA NTRS2016

Command and Data Handling Branch Internship

Modular Integrated Stackable Layers (MISL) is a computer system designed for simple, fast, and cost effective flexible reconfiguration in space environments such as the ISS and Orion projects for various uses. Existing applications include wireless and wired communications, data acquisition and instrumentation, and camera systems, and potential applications include bus protocol converters and subsystem control. MISL is based on Texas Instruments (TI)' MSP430 16-bit ultra-low-power microcontroller device. The purpose of my project was to integrate the MISL system with a liquid crystal display (LCD) touchscreen. The LCD, manufactured by Crystalfontz and part number CFAF320240F-035T-TS, is a 320 by 240 RGB resistive color screen including an optional carrier board. The vast majority of the project was done with Altium Designer, a tool for printed circuit board (PCB) schematic capture, 3D design, and FPGA (Field Programmable Gate Array) development. The new PCB was to allow the LCD to directly stack to the rest of MISL. Research was done with datasheets for the TI microcontroller and touchscreen display in order to meet desired hardware specifications. Documentation on prior MISL projects was also utilized. The initial step was to create a schematic for the LCD, power bus, and data bus connections between components. A layout was then designed with the required physical dimensions, routed traces and vias, power and ground planes, layer stacks, and other specified design rules such as plane clearance and hole size. Multiple consultation sessions were held with Hester Yim, the technical discipline lead for the Command and Data Handling Branch, and Christy Herring, the lead PCB layout designer in the Electronic Design and Manufacturing Branch in order to ensure proper configuration. At the moment, the PCB is awaiting revision by the latter-mentioned branch. Afterwards, the board will begin to undergo the manufacturing and testing process. Throughout the internship at Johnson Space Center, I gained several technical and professional skills. I gained proficiency in Altium Designer and experience using subversion clients, as well as knowledge in PSpice with OrCAD and battery design for spaceflight from on-site. I also gained networking, organization, and communication skills throughout meetings with coworkers and other interns. This internship at Johnson Space Center has impacted my future aspirations by further inspiring me to follow a career path into space rated engineering technology and human spaceflight applications. After graduation, I plan to attend graduate Modular Integrated Stackable Layers (MISL) is a computer system designed for simple, fast, and cost effective flexible reconfiguration in space environments such as the ISS and Orion projects for various uses. Existing applications include wireless and wired communications, data acquisition and instrumentation, and camera systems, and potential applications include bus protocol converters and subsystem control. MISL is based on Texas Instruments’ MSP430 16 bit ultra-low power microcontroller device. The purpose of my project was to integrate the MISL system with a liquid crystal display touchscreen. The LCD, manufactured by Crystalfontz and part number CFAF320240F-035T-TS, is a 320x240 RGB resistive color screen including an optional carrier board.The vast majority of the project was done with Altium Designer, a tool for printed circuit board (PCB) schematic capture, 3D design, and FPGA development. The new PCB was to allow the LCD to directly stack to the rest of MISL. Research was done with datasheets for the TI microcontroller and touchscreen display in order to meet desired hardware specifications. Documentation on prior MISL projects was also utilized. The initial step was to create a schematic for the LCD, power bus, and data bus connections between components. A layout was then designed with the required physical dimensions, routed traces and vias, power and ground planes, layer stacks, and other specified design rules such as plane clearance and hole size. Multiple consultation sessions were held with Hester Yim, the technical discipline lead for the Command and Data Handling Branch, and Christy Herring, the lead PCB layout designer in the Electronic Design and Manufacturing Branch in order to ensure proper configuration. At themoment, the PCB is awaiting revision by the latter-mentioned branch. Afterwards, the board will begin to undergo the manufacturing and testing process.Throughout the internship at Johnson Space Center, I gained several technical and professional skills. I gained proficiency in Altium Designer and experience using subversion clients, as well as knowledge in PSpice with OrCAD and battery design for spaceflight from on-site. I also gained networking, organization, and communication skills throughout meetings with coworkers and other interns. This internship at Johnson Space Center has impacted my future aspirations by further inspiring me to follow a career path into space rated engineering technology and human spaceflight applications. After graduation, I plan to attend graduate school for a master's or doctorate degree in electrical or computer engineering.

Billings, Rachel Mae↗
NASA NTRSDate not supplied

Quick and Correlative TOF-SIMS Analysis of Dispersoid Content in Powder Feedstock and Printed Oxide Dispersion Strengthened Alloys

Oxide dispersion strengthening (ODS) of metal alloys, when combined with additive manufacturing (AM), can be used to solve high-temperature material application problems. The performance of ODS materials is dependent on nano-scale oxide being distributed uniformly throughout the metal matrix; a homogenous distribution is critical to the creep and yield strength. Therefore, quantifying and analyzing these oxide nanoparticles is essential for ODS alloy development. Assessing the chemistry and morphology of dispersoids in a material can be conducted using a variety of X-ray and electron-based methods. Time of Flight Secondary Ion Mass Spectrometry (TOF-SIMS), which assesses chemical concentrations from ion masses, provides the necessary spatial resolution and avoids potential spectral overlap of all elements present. In this work, preparing ODS powder feedstock and Laser Powder Bed Fusion AM was conducted with a NiCoCr alloy and yttria dispersoid, mixed with a Resodyn resonance mixer and printed on an EOS M100 3D printer at NASA Glenn. TOF-SIMS was performed on a Physical Electronics NanoTOF TRIFT V TOF-SIMS at Case Western Reserve University. The TOF-SIMS results collected on the feedstock powder samples correspond to the qualitative interpretation of the homogeneity of the oxide coating on the metal powder from SEM images. This provides quantitative support to the qualitative microscopy images collected earlier in the process design phase. The variance in the yttrium distribution on the powder feedstock samples also correlated with the variance of the yttrium distribution detected in the printed samples. This correlation supported the hypothesis that an even coating of yttria on the metal powders contributes to an even distribution of yttria in the printed material.

Laura G. Wilson↗
NASA NTRS2013

Microwave Sinterator Freeform Additive Construction System (MS-FACS)

The harmful properties of lunar dust, such as small size, glass composition, abnormal surface area, and coatings of imbedded nanophase iron, lead to a unique coupling of the dust with microwave radiation. This coupling can be exploited for rapid sintering of lunar soil for use as a construction material that can be formed to take on an infinite number of shapes and sizes. This work describes a system concept for building structures on the lunar surface using lunar regolith (soil). This system uses the ATHLETE (All-Terrain Hex- Limbed Extra-Terrestrial Explorer) mobility system as a positioning system with a microwave print head (similar to that of a smaller-scale 3D printer). A processing system delivers the lunar regolith to the microwave print head, where the microwave print head/chamber lays down a layer of melted regolith. An arm on the ATHLETE system positions the layer depending on the desired structure.

Howe, Alan S.↗
NASA NTRS2014

NASA's Astromaterials Database: Enabling Research Through Increased Access to Sample Data, Metadata and Imagery

The Astromaterials Acquisition & Curation Office at NASA's Johnson Space Center (JSC) is the designated facility for curating all of NASA's extraterrestrial samples. Today, the suite of collections includes the lunar samples from the Apollo missions, cosmic dust particles falling into the Earth's atmosphere, meteorites collected in Antarctica, comet and interstellar dust particles from the Stardust mission, asteroid particles from Japan's Hayabusa mission, solar wind atoms collected during the Genesis mission, and space‐exposed hardware from several missions. To support planetary science research on these samples, JSC's Astromaterials Curation Office hosts NASA's Astromaterials Curation digital repository and data access portal [http://curator.jsc.nasa.gov/], providing descriptions of the missions and collections, and critical information about each individual sample. Our office is designing and implementing several informatics initiatives to better serve the planetary research community. First, we are re‐hosting the basic database framework by consolidating legacy databases for individual collections and providing a uniform access point for information (descriptions, imagery, classification) on all of our samples. Second, we continue to upgrade and host digital compendia that summarize and highlight published findings on the samples (e.g., lunar samples, meteorites from Mars). We host high resolution imagery of samples as it becomes available, including newly scanned images of historical prints from the Apollo missions. Finally we are creating plans to collect and provide new data, including 3D imagery, point cloud data, micro CT data, and external links to other data sets on selected samples. Together, these individual efforts will provide unprecedented digital access to NASA's Astromaterials, enabling preservation of the samples through more specific and targeted requests, and supporting new planetary science research and collaborations on the samples.

Evans, Cindy↗
NASA NTRS2023

Space Environmental Effects on Additively Manufactured Materials – Results from MISSE-9 and MISSE-10

The NASA Marshall Space Flight Center (MSFC) Space Environmental Effects (SEE) and Contamination Control (CC) teams prepared and characterized MISSE-9 and MISSE-10’s additively manufactured (AM) materials samples to investigate the effect of ultraviolet (UV) radiation, thermal cycling, outgassing, and temperature and provide data on the durability of these samples. Materials studied were polyetherimide (Ultem 1010 and 9085), electrostatic dissipative polyetherketoneketone (ESD-PEKK), also known commercially as Antero 840CN03, polycarbonate biocompatible per ISO 10993 USP Class VI (PC-ISO), and Inconel 718. Some samples were manufactured at MSFC, while 3D printer manufacturers Stratasys and Made In Space, Inc. (MIS) (now Redwire) participated in this effort to compare different vendors and printing setups. Results from nondestructive analyses and tensile testing are presented.

additive manufacturing↗
NASA NTRS2013

Spacecraft 3D Augmented Reality Mobile App

The Spacecraft 3D application allows users to learn about and interact with iconic NASA missions in a new and immersive way using common mobile devices. Using Augmented Reality (AR) techniques to project 3D renditions of the mission spacecraft into real-world surroundings, users can interact with and learn about Curiosity, GRAIL, Cassini, and Voyager. Additional updates on future missions, animations, and information will be ongoing. Using a printed AR Target and camera on a mobile device, users can get up close with these robotic explorers, see how some move, and learn about these engineering feats, which are used to expand knowledge and understanding about space. The software receives input from the mobile device's camera to recognize the presence of an AR marker in the camera's field of view. It then displays a 3D rendition of the selected spacecraft in the user's physical surroundings, on the mobile device's screen, while it tracks the device's movement in relation to the physical position of the spacecraft's 3D image on the AR marker.

Hussey, Kevin J.↗
NASA NTRS2004

Internet Based Simulations of Debris Dispersion of Shuttle Launch

The debris dispersion model (which dispersion model?) is so heterogeneous and interrelated with various factors, 3D graphics combined with physical models are useful in understanding the complexity of launch and range operations. Modeling and simulation in this area mainly focuses on orbital dynamics and range safety concepts, including destruct limits, telemetry and tracking, and population risk. Particle explosion modeling is the process of simulating an explosion by breaking the rocket into many pieces. The particles are scattered throughout their motion using the laws of physics eventually coming to rest. The size of the foot print explains the type of explosion and distribution of the particles. The shuttle launch and range operations in this paper are discussed based on the operations of the Kennedy Space Center, Florida, USA. Java 3D graphics provides geometric and visual content with suitable modeling behaviors of Shuttle launches.

Bardina, Jorge↗
NASA NTRS2008

Review, Selection and Installation of a Rapid Prototype Machine

The objective of this paper is to impress upon the reader the benefits and advantages of investing in rapid prototyping (additive manufacturing) technology thru the procurement of one or two new rapid prototyping machines and the creation of a new Prototype and Model Lab at the Kennedy Space Center (KSC). This new resource will be available to all of United Space Alliance, LLC (USA), enabling engineers from around the company to pursue a more effective means of communication and design with our co-workers, and our customer, the National Aeronautics and Space Administration (NASA). The Rapid Protoyping/3D printing industry mirrors the transition the CAD industry made several years ago, when companies were trying to justify the expenditure of converting to a 3D based system from a 2D based system. The advantages of using a 3D system seemed to be outweighed by the cost it would take to convert not only legacy 2D drawings into 3D models but the training of personnel to use the 3D CAD software. But the reality was that when a 3D CAD system is employed, it gives engineers a much greater ability to conceive new designs and the ability to engineer new tools and products much more effectively. Rapid Prototyping (RP) is the name given to a host of related technologies that are used to fabricate physical objects directly from Computer Aided Design (CAD) data sources. These methods are generally similar to each other in that they add and bond materials in a layer wise-fashion to form objects, instead of machining away material. The machines used in Rapid Prototyping are also sometimes referred to as Rapid Manufacturing machines due to the fact that some of the parts fabricated in a RP machine can be used as the finished product. The name "Rapid Prototyping" is really a misnomer. It is much more than prototypes and it is not always rapid.

McEndree, Caryl↗
NASA NTRS2015

Additive Manufacturing of SiC Based Ceramics and Ceramic Matrix Composites

Silicon carbide (SiC) ceramics and SiC fiber reinforcedSiC ceramic matrix composites (SiCSiC CMCs) offer high payoff as replacements for metals in turbine engine applications due to their lighter weight, higher temperature capability, and lower cooling requirements. Additive manufacturing approaches can offer game changing technologies for the quick and low cost fabrication of parts with much greater design freedom and geometric complexity. Four approaches for developing these materials are presented. The first two utilize low cost 3D printers. The first uses pre-ceramic pastes developed as feed materials which are converted to SiC after firing. The second uses wood containing filament to print a carbonaceous preform which is infiltrated with a pre-ceramic polymer and converted to SiC. The other two approaches pursue the AM of CMCs. The first is binder jet SiC powder processing in collaboration with rp+m (Rapid Prototyping+Manufacturing). Processing optimization was pursued through SiC powder blending, infiltration with and without SiC nano powder loading, and integration of nanofibers into the powder bed. The second approach was laminated object manufacturing (LOM) in which fiber prepregs and laminates are cut to shape by a laser and stacked to form the desired part. Scanning electron microscopy was conducted on materials from all approaches with select approaches also characterized with XRD, TGA, and bend testing.

3-D printing↗
NASA NTRS2015

Custom 3D Printers Revolutionize Space Supply Chain

Under a series of SBIR contracts with Marshall Space Flight Center, start-up company Made In Space, located on the center's campus, developed a high-precision 3D printer capable of manufacturing items in microgravity. The company will soon have a printer installed on the International Space Station, altering the space supply chain. It will print supplies and tools for NASA, as well as nanosatellite shells and other items for public and private entities.

Source record↗