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All sources NASA NTRS DOE OSTI

NASA NTRS2014

3D Printing of Advanced Biocomposites on Earth and Beyond

Human exploration off planet is severely limited by the cost of launching materials into space and re-supply. Thus materials brought from earth must be light, stable and reliable at destination. Using traditional approaches a lunar or Mars base would require either transporting a hefty store of metals or heavy manufacturing equipment and construction materials for in situ extraction; both would severely limit any other mission objectives. Long-term human space presence requires periodic replenishment, adding a massive cost overhead. Even robotic missions often sacrifice science goals for heavy radiation and thermal protection. Biology has the potential to solve these problems because it can replicate and repair itself, and do a wide variety of chemical reactions including making food, fuel and materials. Synthetic biology can greatly enhance and expand life's evolved repertoire. Using natural and synthetically altered organisms as the feedstock for additive manufacturing could one day make possible the dream of producing bespoke tools, food, smart fabrics and even replacement organs on demand. To this end our lab has produced a proof-of-concept bioprinter with nearly one-cell resolution. Genetically engineering yeast cells to secrete bioproducts subsequent to printing allows the potential to make biomaterials with a fine microstructure. Imagine a production system that, at a few micron scale resolution, can add mollusk shell for compressive strength per unit mass, spider silk or collagen for tensile strength per unit mass, and potentially biologically-deposited wires. Now imagine what new products can be enabled by such a technology, on earth or beyond.

Biology↗

NASA NTRS1999

Lithium-Ion Batteries for Aerospace Applications

This presentation reviews: (1) the goals and objectives, (2) the NASA and Airforce requirements, (3) the potential near term missions, (4) management approach, (5) the technical approach and (6) the program road map. The objectives of the program include: (1) develop high specific energy and long life lithium ion cells and smart batteries for aerospace and defense applications, (2) establish domestic production sources, and to demonstrate technological readiness for various missions. The management approach is to encourage the teaming of universities, R&D organizations, and battery manufacturing companies, to build on existing commercial and government technology, and to develop two sources for manufacturing cells and batteries. The technological approach includes: (1) develop advanced electrode materials and electrolytes to achieve improved low temperature performance and long cycle life, (2) optimize cell design to improve specific energy, cycle life and safety, (3) establish manufacturing processes to ensure predictable performance, (4) establish manufacturing processes to ensure predictable performance, (5) develop aerospace lithium ion cells in various AH sizes and voltages, (6) develop electronics for smart battery management, (7) develop a performance database required for various applications, and (8) demonstrate technology readiness for the various missions. Charts which review the requirements for the Li-ion battery development program are presented.

Surampudi, S.↗

NASA NTRS2014

Smart Sensors Gather Information for Machine Diagnostics

Stennis Space Center was interested in using smart sensors to monitor components on test stands and avert equipment failures. Partnering with St. Paul, Minnesota-based Lion Precision through a Cooperative Agreement, the team developed a smart sensor and the associated communication protocols. The same sensor is now commercially available for manufacturing.

Source record↗

NASA NTRS2004

Prepreg and Melt Infiltration Technology Developed for Affordable, Robust Manufacturing of Ceramic Matrix Composites

Affordable fiber-reinforced ceramic matrix composites with multifunctional properties are critically needed for high-temperature aerospace and space transportation applications. These materials have various applications in advanced high-efficiency and high-performance engines, airframe and propulsion components for next-generation launch vehicles, and components for land-based systems. A number of these applications require materials with specific functional characteristics: for example, thick component, hybrid layups for environmental durability and stress management, and self-healing and smart composite matrices. At present, with limited success and very high cost, traditional composite fabrication technologies have been utilized to manufacture some large, complex-shape components of these materials. However, many challenges still remain in developing affordable, robust, and flexible manufacturing technologies for large, complex-shape components with multifunctional properties. The prepreg and melt infiltration (PREMI) technology provides an affordable and robust manufacturing route for low-cost, large-scale production of multifunctional ceramic composite components.

Singh, Mrityunjay↗

NASA NTRS2026

Smart Process Planning for Automated Fiber Placement

Many industries, including aerospace, automotive, wind energy, maritime, and sporting goods, rely on strong, lightweight materials called composites. These materials are made by layering fibers, which can come in the form of narrow strips or wider sheets, and setting them in a polymer matrix. One of the most advanced ways to make these parts is through automated fiber placement, where a machine lays down the fibers in precise patterns. This method can create very efficient and strong designs, but it is complex, expensive, and often depends heavily on the experience of skilled engineers. Today, the design, manufacturing, and inspection stages of composite production are usually handled separately. This separation means that important information, such as how a part will be built or what defects might occur, is not always shared between stages. As a result, parts may not be as lightweight, strong, or defect-free as possible, and the process can take longer and cost more. This research develops a smart process planning system that connects design, manufacturing, and inspection into one continuous process. Built as software that works with existing tools, the system can automatically plan how the fibers are placed, predicting and reducing defects while improving both manufacturability and strength. The system optimizes not only individual layers but also how defects are distributed across all layers, preventing them from stacking up in ways that weaken the final part. It also uses inspection results from completed parts to improve future designs, creating a feedback loop where each stage informs the others. The system was tested by designing a composite panel using this new approach and comparing it to a panel made with state-of-the-art manual planning methods. The results showed that the system could intentionally control where defects appeared and increase the efficiency of the planning process. By unifying design, manufacturing, and inspection, this research shows a way to make advanced composite manufacturing more efficient, consistent, and cost-effective. This approach lowers the barrier to using automated fiber placement and opens the door for its wider adoption not only in aerospace but also in industries such as automotive, wind energy, maritime, and sporting goods, where strong and lightweight structures are essential.

Computer-Aided Process Planning↗

NASA NTRS2023

Emperor's new clothes: Novel textile-based supercapacitors using sheep wool fiber as electrode substrate

Textile-based supercapacitors (TSCs) are being used to meet the ever-increasing demand for mobile, safe, and convenient energy sources to power personal electronic devices. To that end, the smart textiles used in wearable technology need to be made from highly conductive yarns that are easily manufacturable. To date, synthetic- and cellulosic-based yarns have been exclusively used for the fabrication of TSCs, while other yarns have not been explored. Here, we used conductive protein-based yarns for TSCs and report on the use of wool coated with Ti 3 C 2 T x MXene as a potential electrode material. To knit TSCs, wool and cotton yarns were coated with MXene flakes and their surfaces were characterized using Scanning Electron Microscopy (SEM) and X-Ray Photoelectron Spectroscopy (XPS). The electrochemical characterization was conducted to examine the performance of wool- and cotton-based MXene electrodes as substrates and determine charge storage and resistive behavior. These tests showed that wool TSCs exhibited more pseudocapacitive behavior, while cotton TSCs exhibited a wider current range. At a scan rate of 5 mV/s, cotton TSCs presented an areal capacitance of 823.9 mF/cm 2 while this value for the wool TSCs was 284 mF/cm 2 . The performance of yarns was also tested under various mechanical deformation conditions and after washing in order to assess the stability of TSCs. This study indicates the potential of protein-based yarns as electrode substrates for integration of MXene to fabricate smart textile-based devices.

Alyssa Grube↗

NASA NTRS2012

Wireless Self-Acquistion of 12-Lead ECG via Android Smart Phone

Researchers at NASA s Johnson Space Center and at Orbital Research, Inc. (a NASA SBIR grant recipient) have recently developed a dry-electrode harness that allows for self-acquisition of resting 12-lead ECGs by minimally trained laypersons. When used in conjunction with commercial wireless (e.g., Bluetooth(TM) or 802.11-enabled) 12-lead ECG devices and custom smart phone-based software, the collected 12-lead ECG data can also immediately be forwarded from any geographic location within cellular range to the user s physician(s) of choice. The system can also be used to immediately forward to central receiving stations 12-lead ECG data collected during space flight or during activities in any remote terrestrial location supported by an internet or cellular phone infrastructure. The main novel aspects of the system are first, the dry-electrode 12-lead ECG harness itself, and second, an accompanying Android(TM) smart phone-based wireless 12-lead ECG capability. The ECG harness nominally employs dry electrodes manufactured by Orbital Research, Inc, recently cleared through the Food and Drug Administration (FDA). However, other dry electrodes that are not yet FDA cleared, for example those recently developed by Nanosonic, Inc as part of another NASA SBIR grant, can also be used. The various advantageous features of the harness include: 1) laypersons can be quickly instructed on its correct use, remotely if necessary; 2) all tangled "leadwire spaghetti" is eliminated, as is the common clinical problem of "leadwire reversal"; 3) all adhesives and disposables are also eliminated, the harness being fully reusable; if multiple individuals intend to use use the same harness, then standard antimicrobial wipes can be employed to sterilize the dry electrodes (and harness surface if needed) between users; 5) padded cushions at the lateral sides of the torso function to press the left arm (LA) and right arm (RA) dry electrodes mounted on the cushions against sideward or downward-rested arms of the subject; 6) sufficient distal placement of the arm electrodes achieves good electrode abutment to the arms without the need for adhesives, straps, bands, bracelets, or gloves; 7) padding over the sternum avoids "tenting" in the V1 through V3 (and, when present, the V3R) electrode positions; 8) easy-to-don, one-piece design with an adjustable, front-side single point of connection and an adjustable shoulder strap; and 9) Lund or "modified Lund" placement of the dry electrodes, the results of which more effectively reproduce results from "standard" 12-lead ECG placements than do results from Mason-Likar placements. The main limitation of the harness is that "one size does not fit all", meaning that an appropriately sized harness (small, medium, large, etc) must be chosen on the basis of an individual's size. To facilitate the use of the harness with inexpensive, commodity-grade cell phones and tablet devices, 12-lead ECG software is also being developed to accompany the harness for wireless use with Android. For this part of the project, NASA has teamed with TopCoder, Inc and the Harvard-affiliated NASA Tournament Lab in sponsoring java-based software programming contests through TopCoder. While ECG signals from the harness can already be wirelessly received and thoroughly processed (locally or remotely) by commercial-grade conventional (as well as advanced) 12-lead ECG software running on Microsoft Windows(TM), the Android-based software, once completed, will "cast a wider net" by allowing for a greater percentage of cell phone owners to participate in inexpensive, store-and-forward recordings of 12-lead ECGs worldwide, including for example Android cell phone users in many remote, third-world locations. At the time of writing, the Android 12-lead ECG software platform consists of a basic but expanding graphical user interface and accompanying software that: 1) wirelessly receives the 12-lead ECG data stream from a Bluetooth-based, FDA-cleared 12-leaCG device attached to the harness; 2) locally stores the same data in binary format to the SD card on the Android cell phone; and 3) makes the data stream in available in real time, for now to TopCoder's java programming contestants.

Schlegel, Todd T.↗

NASA NTRS1999

Performance Characteristics of Lithium-Ion Cells for Mars Sample Return Athena Rover

In contrast to the primary batteries (lithium thionyl chloride) on the Sojourner Mars Rover and the upcoming 2001 Mars Rover, the Mars Sample Return (MSR) Athena Rover will utilize rechargeable lithium ion batteries, following the footsteps of MSP 2001 Lander. The MSR Athena Rover will contain a rechargeable lithium ion battery of 16 V and a total energy of 150 Wh. The mass and volume of the projected power system will be a maximum of 3 kg and 2 liters, respectively. Each battery consists of twelve cells (6-7 Ah), combined in three parallel strings of four cells (16 V) each, such that the capability of the Rover shall be maintained even in the event of one string failure. In addition to the usual requirements of high specific energy and energy density and long cycle life (100 cycles), the battery is required to operate at wide range of temperatures, especially at sub-zero temperatures down to -20 C. In this paper, we report various performance characterization tests carried out on lithium ion cells, fabricated by different manufacturers under a NASA/DoD lithium ion battery consortium.

Ratnakumar, B. V.↗

NASA NTRSDate not supplied

Additively Manufactured Ink-based Cell Batteries for Flexible Conformational Applications

With the rise of additively manufactured electronics, the importance of thin, flexible printed batteries has increased for shape-conformal electronics. Traditionally, battery cells such as industry-standard lithium-ion batteries, have been rigid and therefore unable to conform to time-variant surfaces such as smart cards/RFID devices, disposable battery-powered skin patches, foldable electronic devices, and IoT nodes. Aligned with the effort to advance technologies on printed electronics for habitat systems and advanced manufacturing, this proof-of-concept will focus on printing a 50 mAh Zn-Ag battery implementing a DIW Technique. After prototype manufacturing, electrical and environmental testing on the flexible battery cell will be conducted to the evaluate energy and power density over 50 charge cycles under standard atmosphere conditions. The project aims to provide PCB designers, fabricators, and assemblers an integrated battery package to eliminate external batteries, external wiring and connectors, and conformational complexity. Potential end uses of the printed battery process will be within Martian and lunar habitat systems, Gateway, and surface vehicles, or aerial robots where space and geometry is a restriction.

Printed Electronics↗

NASA NTRS2015

Biomimetic Fly Eye Sensor for Real-Time Target Tracking

The project objective is to design, build, and demonstrate a biomimetic (inspired by biology) smart sensor based on the common house fly eye for real-time target tracking in three dimensions (3-D). The sensor makes use of revolutionary optical sensor design resulting in significantly improved motion detection capabilities when compared with conventional optical sensors. The design is motivated by the parallel nature of the flys vision system and its demonstrated hyperacuity or precision of visual localization beyond the conventional resolution limit. This means that the sensor is able to accurately detect very fast motion and small changes in motion. The analog architecture of the sensor allows for real-time solution at adjustable bandwidths depending on the application. The low cost, exceptionally lightweight, small form factor, low power requirements, and low computation requirements of the sensor make it ideally suited to many aeronautics applications that have limitations on weight, power, and processing time. The sensor is modular and can be easily adapted in scale and manufactured for a wide variety of sensing applications. Advanced target tracking algorithms will be developed to allow the sensor to track a target in 3-D. These algorithms will be implemented in the smart sensors hardware to enable real-time target tracking.

wing position measurement system↗

NASA NTRS2011

NASA's Space Launch System Progress Report

Exploration beyond Earth will be an enduring legacy for future generations, confirming America's commitment to explore, learn, and progress. NASA's Space Launch System (SLS) Program, managed at the Marshall Space Flight Center, is responsible for designing and developing the first exploration-class rocket since the Apollo Program's Saturn V that sent Americans to the Moon. The SLS offers a flexible design that may be configured for the MultiPurpose Crew Vehicle and associated equipment, or may be outfitted with a payload fairing that will accommodate flagship science instruments and a variety of high-priority experiments. Both options support a national capability that will pay dividends for future generations. Building on legacy systems, facilities, and expertise, the SLS will have an initial lift capability of 70 metric tons (mT) and will be evolvable to 130 mT. While commercial launch vehicle providers service the International Space Station market, this capability will surpass all vehicles, past and present, providing the means to do entirely new missions, such as human exploration of asteroids and Mars. With its superior lift capability, the SLS can expand the interplanetary highway to many possible destinations, conducting revolutionary missions that will change the way we view ourselves, our planet and its place in the cosmos. To perform missions such as these, the SLS will be the largest launch vehicle ever built. It is being designed for safety and affordability - to sustain our journey into the space age. Current plans include launching the first flight, without crew, later this decade, with crewed flights beginning early next decade. Development work now in progress is based on heritage space systems and working knowledge, allowing for a relatively quick start and for maturing the SLS rocket as future technologies become available. Together, NASA and the U.S. aerospace industry are partnering to develop this one-of-a-kind asset. Many of NASA's space centers across the country will provide their unique expertise to the Space Launch System endeavor. Unique infrastructure to be used includes the Michoud Assembly Facility for tank manufacturing, Stennis Space Center for engine testing, and Kennedy Space Center for processing and launch. As this panel will discuss, the SLS team is dedicated to doing things differently-from applying lean oversight/insight models to smartly using legacy hardware and existing facilities. Building on the foundation laid by over 50 years of human and scientific space flight--and on the lessons learned from the Apollo, Space Shuttle, and Constellation Programs-the SLS team has delivered both technical trade studies and business case analyses to ensure that the SLS architecture will be safe, affordable, reliable, and sustainable.

Singer, Joan A.↗

NASA NTRS1991

Systematic Identification Of Discrepant Hardware

CAMRAD, program designed for rapid input and retrieval of all data used in engineering-to-manufacturing support operations, aids engineer by automating material-review-disposition process. Facilitates research of material-review histories and provides for efficient processing of material-review documents. Three SmartWare project files control operation. Written in Smart programming language and designed to run on IBM PC compatibles with SmartWave version 3.1.

Hanna, Timothy L.↗

NASA NTRS2007

NASA Tech Briefs, June 2007

Topics covered include: High-Accuracy, High-Dynamic-Range Phase-Measurement System; Simple, Compact, Safe Impact Tester; Multi-Antenna Radar Systems for Doppler Rain Measurements; 600-GHz Electronically Tunable Vector Measurement System; Modular Architecture for the Measurement of Space Radiation; VLSI Design of a Turbo Decoder; Architecture of an Autonomous Radio Receiver; Improved On-Chip Measurement of Delay in an FPGA or ASIC; Resource Selection and Ranking; Accident/Mishap Investigation System; Simplified Identification of mRNA or DNA in Whole Cells; Printed Multi-Turn Loop Antennas for RF Biotelemetry; Making Ternary Quantum Dots From Single-Source Precursors; Improved Single-Source Precursors for Solar-Cell Absorbers; Spray CVD for Making Solar-Cell Absorber Layers; Glass/BNNT Composite for Sealing Solid Oxide Fuel Cells; A Method of Assembling Compact Coherent Fiber-Optic Bundles; Manufacturing Diamond Under Very High Pressure; Ring-Resonator/Sol-Gel Interferometric Immunosensor; Compact Fuel-Cell System Would Consume Neat Methanol; Algorithm Would Enable Robots to Solve Problems Creatively; Hypothetical Scenario Generator for Fault-Tolerant Diagnosis; Smart Data Node in the Sky; Pseudo-Waypoint Guidance for Proximity Spacecraft Maneuvers; Update on Controlling Herds of Cooperative Robots; and Simulation and Testing of Maneuvering of a Planetary Rover.

Source record↗

NASA NTRS1984

Big Savings from Smart Motors

Chesebrough-Pond's operates 32 plants across the nation and in those plants are more than 10,000 electric motors. In an effort to cut down on waste of electrical power used by these motors, Chesebrough organized a Corporate Advanced Technology Group to devise ways of improving productivity and cut manufacturing costs. Chesebrough used NASA's Marshall Space Flight Center's Power Factor Controller technology as a departure point for development of their own computerized motor controller that enables motors to operate at maximum efficiency regardless of the motor's applications or operating condition.

Source record↗

NASA NTRS2003

Impedance-Based Structural Health Monitoring for Composite Laminates at Cryogenic Environments

One of the important ways of increasing the payload in a reusable launch vehicle (RLV) is to replace heavy metallic materials by lightweight composite laminates. Among various parts and systems of the RLV, this project focuses on tanks containing cryogenic fuel. Historically, aluminum alloys have been used as the materials to construct fuel tanks for launch vehicles. To replace aluminum alloys with composite laminates or honeycomb materials, engineers have to make sure that the composites are free of defects before, during, and after launch. In addition to robust design and manufacturing procedures, the performance of the composite structures needs to be monitored constantly.In recent years, the impedance-based health monitoring technique has shown its promise in many applications. This technique makes use of the special properties of smart piezoelectric materials to identify the change of material properties due to the nucleation and progression of damage. The piezoceramic patch serves as a sensor and an actuator simultaneously. The piezoelectric patch is bonded onto an existing structure or embedded into a new structure and electrically excited at high frequencies. The signature (impedance or admittance) is extracted as a function of the exciting frequency and is compared with the baseline signature of the healthy state. The damage is quantified using root mean square deviation (RMSD) in the impedance signatures with respect to the baseline signature. A major advantage of this technique is that the procedure is nondestructive in nature and does not perturb the properties and performance of the materials and structures. This project aims at applying the impedance-based nondestructive testing technique to the damage identification of composite laminates at cryogenic temperature.

Tseng, Kevin↗

NASA NTRS2008

Compliance and Functional Testing of IEEE 1451.1 for NCAP-to-NCAP Communications in a Sensor Network

Distributed control in a networked environment is an irreplaceable feature in systems with remote sensors and actuators. Although distributed control was not originally designed to be networked, usage of off-the-shelf networking technologies has become so prevalent that control systems are desired to have access mechanisms similar to computer networks. However, proprietary transducer interfaces for network communications and distributed control overwhelmingly dominate this industry. Unless the lack of compatibility and interoperability among transducers is resolved, the mature level of access (that computer networking can deliver) will not be achieved in such networked distributed control systems. Standardization of networked transducer interfaces will enable devices from different manufacturers to talk to each other and ensure their plug-and-play capability. One such standard is the suite of IEEE 1451 for sensor network communication and transducer interfaces. The suite not only provides a standard interface for smart transducers, but also outlines the connection of an NCAP (network capable application processor) and transducers (through a transducer interface module TIM). This paper presents the design of the compliance testing of IEEE 1451.1 (referred to as Dot1) compatible NCAP-to-NCAP communications on a link-layer independent medium. The paper also represents the first demonstration of NCAP-to-NCAP communications with Dot1 compatibility: a tester NCAP and an NCAP under test (NUT).

Figueroa, Jorge↗

NASA NTRS2003

Testing Update on 20 and 25-Ah Lithium Ion Cells

Eagle-Picher Energy Products has worked on lithium ion batteries for approximately 8 years. During that period EPEPC developed and delivered several cell sizes on a program funded by the USAF and Canadian DND. Designs are wound cylindrical cells from 7 to 40-Ah. Most cells delivered were approximately 25-Ah due to requirements of Mars missions. Several iterations of cells were manufactured and delivered for evaluation. The first design was 20-Ah, Design I, and the second was a 25-Ah, Design II.

Bruce, Gregg C.↗

NASA NTRS2008

Assessment of Various Low Temperature Electrolytes in Prototype Li-Ion Cells Developed for ESMD Applications

Due to their attractive properties and proven success, Li-ion batteries have become identified as the battery chemistry of choice for a number of future NASA missions. A number of these applications would be greatly benefited by improved performance of Li-ion technology over a wider operating temperature range, especially at low temperatures, such as future ESMD missions. In many cases, these technology improvements may be mission enabling, and at the very least mission enhancing. In addition to aerospace applications, the DoE has interest in developing advanced Li-ion batteries that can operate over a wide temperature range to enable terrestrial HEV applications. Thus, our focus at JPL in recent years has been to extend the operating temperature range of Li-ion batteries, especially at low temperatures. To accomplish this, the main focus of the research has been devoted to developing improved lithium-ion conducting electrolytes. In the present paper, we would like to present some of the results we have obtained with six different ethylene carbonate-based electrolytes optimized for low temperature. In addition to investigating the behavior in experimental cells initially, the performance of these promising low temperature electrolytes was demonstrated in large capacity, aerospace quality Li-ion prototype cells, manufactured by Yardney Technical Products and Saft America, Inc. These cells were subjected to a number of performance tests, including discharge rate characterization, charge rate characterization, cycle life performance at various temperatures, and power characterization tests.

Wide Operating Temperature Electrolytes↗