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Contamination monitoring of the OSIRIS-REx ISO5 asteroid sample cleanroom

The OSIRIS-REx mission to asteroid Bennu successfully collected hundreds of grams of asteroid regolith in October 2020 [1]. The spacecraft departed Bennu in May 2021 for Earth return and will release the sample canister to be recovered in Utah in September 2023 [2]. Samples will be transported to the curation facility at NASA Johnson Space Center, where an ISO5 equivalent cleanroom has been designed in 2017 and completed in 2021. Aspects of the design and material selection for the cleanroom and its supporting facilities (air handling system, cleanroom floors and walls, filters, paints, etc.) were optimized to minimize effects of organic and inorganic contaminants and offgassing [3]. Since its completion, the lab has been carefully monitored to understand and establish a baseline with respect to multiple environmental aspects – measurement of particle counts, deploying Si wafer witness plates for organic and inorganic contaminants, deploying aluminum foils for a focus on organics with JSC in-house expertise, gas samples, and regular microbial and fungal measurements on selected surfaces and air samples in the cleanroom. This contribution will report on nearly one year of monitoring and highlight several specific aspects that have led to a better understanding of the new cleanroom environment.

carbonaceous asteroid

A recent Cleanroom success story: The Redwing project

Redwing is the largest completed Cleanroom software engineering project in IBM, both in terms of lines of code and project staffing. The product provides a decision-support facility that utilizes artificial intelligence (AI) technology for predicting and preventing complex operating problems in an MVS environment. The project used the Cleanroom process for development and realized a defect rate of 2.6 errors/KLOC, measured from first execution. This represents the total amount of errors that were found in testing and installation at three field test sites. Development productivity was 486 LOC/PM, which included all development labor expended in design specification through completion of incremental testing. In short, the Redwing team produced a complex systems software product with an extraordinarily low error rate, while maintaining high productivity. All of this was accomplished by a project team using Cleanroom for the first time. An 'introductory implementation' of Cleanroom was defined and used on Redwing. This paper describes the quality and productivity results, the Redwing project, and how Cleanroom was implemented.

Hausler, Philip A.

Characterization of Biological Fallout Particles of Cleanrooms to Measure Spacecraft Cleanliness

NASA cleanrooms are humidity, temperature-regulated, and particle contaminant-controlled environments used for spacecraft assembly. Microorganisms, which are crucial contaminants shed from humans and transported through the environment, can adapt to the oligotrophic cleanroom conditions. These biogenic particles need to be identified to extend our knowledge of biological contamination for future NASA mission use. Here, we devised an aluminum coupon with polycarbonate filter setup to collect fallout particles from an ISO 5 and an ISO 7 cleanroom. We demonstrated the presence of microbial particles, as standalone entities and associated with inert particles in cleanroom environments. The contamination was confirmed as biogenic in virtue of estimating the elemental composition of individual and aggregated particles using an epifluorescence and Field Emission Scanning Electron Microscopy (FESEM) coupled with an energy dispersive X-ray analysis (EDX). Epifluorescence microscopy showed that the particles were stained less (25%) with SYTO 9 and more (75%) with propidium iodide, suggesting that the suspected biogenic particles are membrane-compromised. Remarkably, biological particles such as bacteria and fungal spores/hyphae were observed at sizes ranging from 2 to 70 µm, with abundant C and O elemental signatures and essential tracers (Na, Mg, K, Ca and Cl). Inert particles (2 to 500 µm) that were characterized included compositions such as silica (SiO2), aluminosilicates (Al, Si), and carbonaceous fibers. Furthermore, we designed and illustrated a unique correlative epifluorescence and FE-SEM method to strengthen this approach by acquiring the same biogenic particles in the same filter coupon for a one-to-one comparison. Interestingly, the SYTO 9 stained particles showed abundant C and O elemental signature implying that they are viable microbial particles. Constant evaluation of cleanroom biological and inert particles will help to characterize biological contamination for future NASA missions (e.g. Mars 2020).

Malli Mohan, Ganesh Babu

Application of Whole Genome Sequencing and MALDI-TOF to the Identifcation of Bacillus Species Isolated from Cleanrooms at NASA Johnson Space Center

Astromaterial cleanrooms at NASA Johnson Space Center are built environments that hold samples, such as lunar rocks, from different space exploration missions. Bacillus sp. are frequently detected in routine microbial monitoring of these facilities. Since this, and related genera, can form endospores that can withstand harsh conditions, they could contaminate astromaterials. This could confound searches for extraterrestrial life. Whole genome sequencing (WGS) is widely used for identifying bacterial strains and tracking their source; however, WGS is expensive and time consuming. Matrix-assisted laser desorption ionization– time of flight mass spectrometry (MALDI-TOF) shows promise as a low-cost, rapid method of identifying strains of bacteria, but few studies have compared this proteomics method to WGS. To evaluate a high throughput method of tracking the source of contamination of this built environment, WGS and MALDI-TOF was conducted on 18 bacterial strains isolated from surfaces in astromaterials cleanrooms. WGS identified 14 Bacillus, 2 Paenibacillus, 1 Solibacillus and 1 Alcaligenes strains. These isolates showed similarity to strains commonly observed in spacecraft assembly cleanrooms at other facilities. Cluster analysis of mass spectra generated by MALDI-TOF grouped strains together that were greater than 94% similar to each other in terms of amino acid sequences of single copy core genes, as assessed by WGS. This suggests that MALDI-TOF and WGS results are consistent with each other and MALDI-TOF can rapidly identify strains of Bacillus sp. isolated from cleanroom environments with a resolution comparable to WGS. Based on phylogenomic analysis, these results also suggest the presence of a cosmopolitan class of Bacillus sp. that are more likely to be found in cleanrooms and similar built environments than in natural systems.

Farnaz Mazhari

Enumeration and Fluorescence In Situ Hybridization of Microbial Bioburden on Cleanroom Surfaces

Introduction: Microorganisms are everywhere on Earth, even in the cleanest of places. Spacecraft assembly cleanrooms can harbor low levels of living and dead microbial cells (e.g., [1,2]), and cleanroom bioburden can also include organic molecules from industrial sources and in situ biomass. Life detection missions require careful attention to avoid contaminants that can be easily convoluted with analytical targets. We are evaluating epifluorescent microscopy and fluorescence in situ hybridization (FISH) as methods to complement organic contamination detection techniques. Epifluorescent cell counting offers an accurate and cost-effective way to quantify low levels of surface biomass. FISH could allow for the identification of residual organisms, and can be targeted to detect active populations of specific organisms such as bacteria known to resist cleaning procedures. This effort is part of a larger study that is concentrated on characterizing the surface and airborne molecular organic contamination background in Johnson Space Center (JSC) Astromaterials curation laboratories and Goddard Space Flight Center (GSFC) spacecraft assembly rooms, and understanding contaminants in the context of cleaning procedures and residual bioburden. Methods: Samples were collected by swabbing surfaces in ISO 5 and ISO 7 equivalent cleanrooms at JSC. Swabs for FISH were fixed in 4% paraformaldehyde (PFA) for 3 hours and then stored in 1:1 ethanol:PBS, while swabs for cell counting were stored in 4% PFA until analysis to avoid any cell loss during centrifugation that could impact quantification of very low biomass samples. Cell counting was performed with SYBR Gold as in [3], but adapted for very low biomass. FISH was performed as in [4], using DAPI as a counterstain for all DNA-containing cells. Negative controls included wells with no probe applied, to test for natural fluorescence, as well as the nonsense probe NONEUB (reverse complement of EUB338) to evaluate non-specific probe binding. Results and Discussion: Cleanroom surfaces had 102-103 cells cm-2. The extremely low biomass of these samples was challenging for enumeration, and required careful and routine use of “field” and laboratory blanks. FISH was performed with the general archaeal and bacterial probes ARCH915 and EUB338 (EUBMIX, [4]), probe GAMBET ([4]), and PSE227, which targets the genus Pseudomonas [5]). The latter two probes were selected because Pseudomonas spp. and other Gammaproteobacteria have not been isolated from cleanroom surfaces but do appear frequently in rRNA gene libraries from these surfaces. While some active bacteria were identified (Fig. 1c), most cells detectable by DAPI did not have a strong or any fluorescent signal (e.g., Fig. 1d), indicating that the vast majority of cells are dead or inactive. This suggests that cleaning protocols are effective at inactivating microbial contaminants, but that dead or inactive cells can remain on surfaces. Cells were often clumped in a weakly autofluorescent matrix, possibly biofilm material (Fig. 1c,d). We also observed other particulate material that was collected by the swabs, including apparent textile fibers (Fig. 1b). Our results are consistent with other studies that show that the bioburden present in clean rooms includes active, dormant, and dead cells. We will discuss how FISH and epifluorescent cell counting could be applied in planetary protection protocols, including the advantages and disadvantages of FISH and cell counting for routine use, as well as different possible applications for more specialized FISH procedures. References: [1] Moissl-Eichinger et al. (2015) Sci Rep, 5, 9156 [2] Hendrickson et al. (2021) Microbiome, 9, 238 [3] Jones et al. (2017) Appl Environ Microbiol, 83, e00909-17 [4] Jones et al. (2015) Appl Environ Microbiol, 81, 1242-1250. [5] Watt et al. (2006) Environ Microbiol, 8, 871-884

C J Huff

Insights From Routine Microbiological Monitoring of Air in Astromaterials Curation Cleanrooms

NASA maintains nine separate cleanrooms at the Johnson Space Center to curate and preserve astromaterials samples. Routine microbial monitoring of the surfaces in these cleanrooms began in 20181. Until recently, materials compatibility requirements prevented monitoring airborne biological particles in all but one of these cleanrooms. New astromaterials collections from carbon rich asteroids are more susceptible to biological degradation than previous collections. Therefore, it is important to monitor the bioburden in the air and on surfaces in these labs. Establishing a comprehensive microbial monitoring program will help inform the monitoring and curation plans for Mars sample return which will include samples that are extremely biologically sensitive. In April of 2022 we began routinely collecting air samples in seven of the nine curation cleanrooms (Meteorite ISO 7 equivalent, Lunar ISO 6 equivalent, Stardust, Hayabusa2, OSIRIS-REx ISO 5 equivalent, and Genesis ISO 4 equivalent) using a sampling device that collects airborne biological particles on an electret filter instead conventional sampler that collect cells in a liquid media or onto organic rich Petri dishes. Electret is a generic term for electrostatically charged media. The charge on these materials increases particle trapping when compared to non-charged filters of similar thickness. N95 respirators also use electret filters. This dry sample collection method allows us to meet materials requirements for all the curation labs and reduces the risk of inadvertently introducing contamination as part of our monitoring effort. This method also allows us to preserve a portion of each sample for DNA extraction and next generation sequencing. DNA sequencing helps us to characterize the portion of the cleanroom microbiome that we cannot culture. We will present the results of our first 8 months of monitoring, compare these results to particle counts in the labs and to measurements made directly onto Petri dishes when possible. We will also make recommendations for modifications to the sampling method to improve sampling efficiency and preserve diversity.

A. B. Regberg

Cleanroom Contamination Identification Method Development

During fabrication, assembly, and testing of spacecraft and flight hardware it is vital to avoid contaminants that can cause degradation and could result in significant failure. Yet, there is no existing contamination monitoring method that provides the identity of airborne particles in a cleanroom facility. Knowing the particle identities, would allow scientists and engineers to determine the source of the contaminants and prevent setbacks before they occur or cause damage. Current cleanliness monitoring methods include airborne particle counters (APCs), fallout filters, and visual inspections. Particle counts from APCs are the primary metric used to define a cleanroom class and hence its level of cleanliness, but do not provide identification nor can they differentiate between large and small sizes of particles. In addition, using fallout filters is not a proactive, timely, or representative approach to cleanroom contamination monitoring because these samples are only retrieved after 30 days and are placed away from spacecraft processing to avoid interference with operations. In contrast, the forced air sampling method can collect a sample within an hour at any location required and provide results in less than a day. This system uses a cassette and filter sample medium to capture airborne particles which are then taken to a scanning electron microscope with energy dispersive spectroscopy (SEM/EDS) to identify and size the captured particles. Development of forced air sampling into an established laboratory capability will allow for fast sampling and routine identification of unknown contamination sources within the cleanroom. The test method development required market research for an air sampling cassette that increases sample collection efficiency and a filter with low enough background contamination to allow differentiation between a blank (control) and the collected sample. It was determined that a conductive black cassette and a polycarbonate filter were the best options. Conductive black cassettes, in comparison to the standard styrene, are manufactured using polypropylene filled with carbon. This makes the cassette conductive and minimizes the tendency of particles to stick to the wall of the cassette due to electrostatic force. In previous trials a mixed cellulose ester (MCE) filter was used to capture the contaminants, however the rougher surface of the filter contributed to entrapment of the particles within the filter structure and made it harder to identify the particles. In comparison, track etched polycarbonate filters have random cylindrical pores and a smooth surface which contributes to uniform sample distribution on the surface of the filter. Future work includes: testing the system using control samples to determine the efficiency and suitability of the medium, performing sample collection in various environments to establish ideal operating parameters and analyzing contaminant particles using SEM/EDS and assistant characterization techniques. Once fully developed, employing the forced air sampling method will help to prevent damage to spacecraft, avoid schedule delays, and allow for mission success.

Hernandez Melendez, Jailyn M.

Resolution of Maldi-Tof Compared to Whole Genome Sequencing for Identification of Bacillus Species Isolated From Cleanrooms at Nasa Johnson Space Center

The Astromaterials Acquisition and Curation Office at NASA Johnson Space Center maintains cleanrooms to archive extraterrestrial materials returned from space exploration missions. Compared to typical built environments, oligotrophic conditions make these facilities inhospitable to microbes. Despite these controls, bacteria and fungi are regularly cultured from these cleanrooms. In particular, Bacillus sp. are frequently isolated during routine microbial monitoring. Endospores associated with this genus can survive extreme environments, such as cleanrooms. This microbial contamination may affect the integrity of astromaterials.

Microbiology

Cleanroom software development

The 'cleanroom' software development process is a technical and organizational approach to developing software with certifiable reliability. Key ideas behind the process are well structured software specifications, randomized testing methods and the introduction of statistical controls; but the main point is to deny entry for defects during the development of software. This latter point suggests the use of the term 'cleanroom' in analogy to the defect prevention controls used in the manufacturing of high technology hardware. In the 'cleanroom', the entire software development process is embedded within a formal statistical design, in contrast to executing selected tests and appealing to the randomness of operational settings for drawing statistical inferences. Instead, random testing is introduced as a part of the statistical design itself so that when development and testing are completed, statistical inferences are made about the operation of the system.

Dyer, M.

Cleanroom Contaminant Monitor

Under a Small Business Innovation Research (SBIR) contract from Kennedy Space Center (KSC), Femtometrics, Inc. developed the Real-Time Non-Volatile Residue (NVR) monitor. Criteria established by KSC called for a technology that could regulate the accumulation of nonvolatile residues in cleanroom environments. The company accommodated the Center's need with an advanced, highly sensitive surface acoustic wave (SAW) microsensor capable of detecting sub-monolayer deposition in cleanrooms where aerospace systems are assembled. Years earlier, Femtometrics responded to and received SBIR contracts from Langley Research Center for highly sensitive aerosol detectors for environmental researchers. Stimulated by the SBIR wins, the company set about to develop the SAW resonator technology. A new type of sensor has evolved from the research, one that has the ability to measure a range of chemical vapors by applying chemical-specific coating on the sensing surface. Commercial applications of the Real-Time NVR include Class 1 cleanrooms at semiconductor and hard-disk manufacturing plants.

Source record

A Dynamic Approach to Monitoring Particle Fallout in a Cleanroom Environment

This slide presentation discusses a mathematical model to monitor particle fallout in a cleanroom. "Cleanliness levels" do not lead to increases with regards to cleanroom type or time because the levels are not linear. Activity level, impacts the cleanroom class. The numerical method presented leads to a simple Class-hour formulation, that allows for dynamic monitoring of the particle using a standard air particle counter.

Perry, Radford L., III

Recovery Rate is an Improved Metric for Monitoring Bioburden in Cleanrooms

The Astromaterials Acquisition and Curation Office maintains seven cleanrooms for curating extraterrestrial samples from a variety of sample return missions. These cleanrooms are monitored for inorganic and particulate contamination and are maintained at ISO 7 to ISO 4 equivalent standards as dictated by collection requirements. As part of the advanced curation effort and to prepare for future sample collections from carbonaceous asteroids and eventually Mars we have begun monitoring the microbiology of these cleanrooms. Insights gained from monitoring these labs can be applied to improving planetary protection efforts.

Planetary Protection

Congruence of Clusters Defined By Whole Genome Sequencing and MALDI-TOF for Bacteria Isolated From Cleanrooms

Introduction: Oligotrophic conditions can render cleanrooms inhospitable to microbes. Despite these constraints, fungi and bacteria are frequently isolated from surfaces in astromaterials cleanrooms at the Johnson Space Center. Bacillus species are of particular concern because endospores belonging to this genus are resilient and can affect astromaterials. Current monitoring programs rely on 16S rRNA sequencing and the VITEK2 Compact system. These methods have limited power to resolve Bacillus species. Matrix-assisted laser desorption - time of flight mass spectrometry (MALDI-TOF MS), provides a rapid, low cost, method of identifying bacterial isolates and has a higher resolution than 16S rRNA sequencing, particularly for Bacillus species; however, few studies have compared this method to the industry gold standard, whole genome sequencing (WGS). Methods: Based on 16S rRNA classification, we selected 14 isolates for analysis with MALDI-TOF and WGS. Mass spectra were generated with MALDI-TOF MS and processed with custom scripts to identify clusters of closely related isolates and calculate a matrix of pairwise cosine similarity scores. Hybrid Illumina and Nanopore sequencing were used to generate draft genomes. Pairwise similarity scores were calculated from these genomes based on the average amino acid identity (AAI) predicted from single copy core genes. Congruence of clustering between these methods, was assessed by calculating adjusted Rand and Wallace coefficients. Results: Clusters of species generated from MALDI-TOF MS showed good agreement of phylotypes generated with WGS. Pairs of strains that were > 94% similar to each other in terms of predicted amino acid sequences consistently showed cosine similarities of mass spectra > 0.65 and, of the 9 clusters identified with WGS, 8 were identical with MALDI-TOF. This corresponds to an adjusted Rand index of 0.95 and a 95% confidence interval of 0.80 – 1.00 for adjusted Wallace coefficients. The only discordance was for a pair of isolates that were classified as Paenibacillus species. This pair showed relatively high similarity (0.84) in terms of MALDI-TOF MS but only 85% similarity in terms of AAI. Conclusion: This study shows that MALDI-TOF and WGS exhibit a similar ability to delineate Bacillus species isolated from cleanrooms and taxonomic units described by these two methods are consistent with one another. Since MALDI-TOF MS is low in cost and high in throughput, this approach appears to be an ideal option for routine microbial monitoring and identifying Bacillus species.

Farnaz Mazhari

Clean is not Sterile: A Planetary Science and Planetary Protection Perspective on Cleanroom Microbiology at NASA

The Astromaterials Acquisition and Curation Office at NASA is responsible for the curation of extraterrestrial samples from NASA’s past and future sample return missions. Our office curates samples from the moon, meteorites, comets, asteroids, cosmic dust and solar wind particles. All these samples are kept in cleanrooms to limit particulate and trace metal contamination, but none of these cleanrooms are specifically designed to control microbial contamination. During the early Apollo missions NASA scientists were very concerned with protecting the Earth from potential microbial contamination from the moon and with protecting the lunar samples from terrestrial microbes. NASA developed specialized equipment and clean rooms to keep these collections pristine. However, as we learned more about the lunar environment our concerns about microbial contamination lessened. Today none of the existing collections have microbial contamination requirements because they are not considered susceptible to microbial alteration under curation conditions (e.g. solar wind samples, and lunar samples) or have already been contaminated by terrestrial biology (meteorites collected in Antarctica). However, NASA’s OSIRIS-REx mission will land in 2023 with samples from a carbon rich asteroid that will be susceptible to microbial alteration. The Perseverance rover on Mars will begin to collect and cache samples that will be returned to Earth as soon as 2031. Martian samples may contain signs of extraterrestrial life and will have to be treated like the early Apollo samples. Martian samples will be isolated to protect the Earth, and must also be protected from terrestrial contamination. I will present microbial monitoring data from existing NASA cleanrooms and discuss how NASA is planning to use techniques from the pharmaceutical industry and academia to design new laboratories and equipment that will protect astromaterials and the earth from unwanted microbial contamination. I will also discuss a project to sample the external microbiome of the International Space Station. Results from this research will be used to design facilities for use on Mars that limit the amount of contamination associated with crewed missions.

Aaron B Regberg

Upgrades to NASA's Largest Cleanroom

NASA’s largest cleanroom built in 1989. Certified ISO 7 cleanroom originally designed to support 2 simultaneous shuttle missions.

Cleanroom

Microsystems Fabrication Laboratory-New Class 100 Cleanroom Completed and Certified

A new Microsystems Fabrication Laboratory (MFL), a Class 100 cleanroom fabrication facility, was completed and certified in 2002 at the NASA Glenn Research Center. This facility, to be used by Glenn's Instrumentation and Controls Division, was designed and built as part of the NASA Construction of Facilities Program. The design, construction, and certification phases were managed by personnel from Glenn s Facilities and Test Engineering Division. Because of time constraints and the need for specialized cleanroom expertise, this 1000 ft2 laboratory was completed using a design-build procurement. Facility Planning & Resources (Pittsburgh, PA) was selected as the prime contractor and provided the architectural design and project management. A major subcontractor, AdvanceTEC, LLC (Richmond, VA), provided the mechanical and electrical design and performed the construction services. Throughout this fast-track project, Facilities and Test Engineering Division personnel provided overall project management and worked closely with the contractors to ensure that the customers needs were addressed and that the impact of the project implementation was minimized.

Borato, Frances M.

Cleanroom Design Practices and Their Influence on Particle Counts

This paper will discuss the adverse effects of deficient cleanroom design practices on airborne particle counts and the rather curious correlation of particle count variations with external environmental pressure fluctuations. Data is also presented that demonstrates that APL building 23 cleanrooms ran well below ISO class 7 (FED class 10,000) during New Horizons and STEREO integration.

Hogue, Patrick

Hardy Bacterium Isolated From Two Geographically Distinct Spacecraft Assembly Cleanroom Facilities

Earlier studies have confirmed that a tenacious hardy bacterial population manages to persist and survive throughout a spacecraft assembly process. The widespread detection of these organisms underscores the challenges in eliminating them completely. Only comprehensive and repetitive microbial diversity studies of geographically distinct cleanroom facilities will bolster the understanding of planetary protection relevant microbes. Extensive characterizations of the physiological traits demonstrated by cleanroom microbes will aid NASA in gauging the forward contamination risk that hardy bacteria (such as Tersicoccus phoenicis) pose to spacecraft. This study reports on the isolation and identification of two gram-positive, non-motile, non-spore-forming bacterial strains from the spacecraft assembly facilities at Kennedy Space Center, Florida, USA and Centre Spatial Guyanais, Kourou, French Guiana. DNA-DNA relatedness values between the novel strains indicates that these novel strains were indeed members of a same species. Phylogenetic evidence derived from a 16S ribosomal DNA analysis indicated that both the novel strains are less closely related to all other Arthrobacter species.

Vaisham-payan, Parag A.