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NASA's In-Space Manufacturing Project: A Roadmap for a Multimaterial Fabrication Laboratory in Space

Human space exploration to date has been limited to low Earth orbit and the moon. The International Space Station (ISS) provides a unique opportunity for NASA to partner with private industry for development and demonstration of the technologies needed to support exploration initiatives. One challenge that is critical to sustainable and safer exploration is the ability to manufacture and recycle materials in space. This paper provides an overview of NASA's in-space manufacturing (ISM) project, its past and current activities (2014-2017), and how technologies under development will ultimately culminate in a multimaterial fabrication laboratory ("ISM FabLab") to be deployed on the International Space Station in the early 2020s. ISM is a critical capability for the long endurance missions NASA seeks to undertake in the coming decades. An unanticipated failure that can be adapted for in low earth orbit, through a resupply launch or a return to earth, may instead result in a loss of mission while in transit to Mars. To have a suite of functional ISM capabilities that are compatible with NASA's exploration timeline, ISM must be equipped with the resources necessary to develop these technologies and deploy them for testing prior to the scheduled de-orbit of ISS in 2024. The presentation provides a broad overview of ISM projects activities culminating with the Fabrication Laboratory for ISS. In 2017, the in-space manufacturing project issued a broad agency announcement for this capability. Requirements of the Fabrication Laboratory as stated in the solicitation will be discussed. The FabLab will move NASA and private industry significantly closer to changing historical paradigms for human spaceflight where all materials used in space are launched from earth. While the current ISM FabLab will be tested on ISS, future systems are eventually intended for use in a deep space habitat or transit vehicle. The work of commercial companies funded under NASA's Small Business Innovative Research Program (SBIR) is also discussed, as these activities, from development of recyclable packaging for ISS to additive manufacturing capabilities for metals and electronics, could also potentially be infused into future exploration capabilities. Key data from ISM projects to date will also be summarized.

Prater, Tracie↗

NASA's In-Space Manufacturing Project: Toward a Multimaterial Fabrication Laboratory for the International Space Station

uman space exploration to date has been limited to low Earth orbit and the moon. The International Space Station (ISS) provides a unique opportunity for NASA to partner with private industry for development and demonstration of the technologies needed to support exploration initiatives. One challenge that is critical to sustainable and safer exploration is the ability to manufacture and recycle materials in space. This paper provides an overview of NASA's in-space manufacturing (ISM) project, its past and current activities, and how technologies under development will ultimately culminate in a multimaterial fabrication laboratory ("ISM FabLab") to be deployed on the International Space Station in the early 2020s. ISM is a critical capability for the long endurance missions NASA seeks to undertake in the coming decades. An unanticipated failure that can be adapted for in low earth orbit, through a resupply launch or a return to earth, may instead result in a loss of mission while in transit to Mars. To have a suite of functional ISM capabilities that are compatible with NASA's exploration timeline, ISM must be equipped with the resources necessary to develop these technologies and deploy them for testing prior to the scheduled de-orbit of ISS in 2024. The paper provides a broad overview of ISM projects activities culminating with the Fabrication Laboratory for ISS. The FabLab will move NASA and private industry significantly closer to changing historical paradigms for human spaceflight where all materials used in space are launched from earth. While the current ISM FabLab will be tested on ISS, future systems are eventually intended for use in a deep space habitat or transit vehicle. The work of commercial companies funded under NASA's Small Business Innovative Research Program (SBIR) is also discussed, as these activities, from development of recyclable packaging for ISS to additive manufacturing capabilities for metals and electronics, could also potentially be infused into FabLab exploration capabilities as well.

Prater, Tracie↗

Technical support package: Large, easily deployable structures. NASA Tech Briefs, Fall 1982, volume 7, no. 1

Design and test data for packaging, deploying, and assembling structures for near term space platform systems, were provided by testing light type hardware in the Neutral Buoyancy Simulator. An optimum or near optimum structural configuration for varying degrees of deployment utilizing different levels of EVA and RMS was achieved. The design of joints and connectors and their lock/release mechanisms were refined to improve performance and operational convenience. The incorporation of utilities into structural modules to determine their effects on packaging and deployment was evaluated. By simulation tests, data was obtained for stowage, deployment, and assembly of the final structural system design to determine construction timelines, and evaluate system functioning and techniques.

Source record↗

Overview of the Mars Science Laboratory Parachute Decelerator Subsystem

In 2010 the Mars Science Laboratory (MSL) mission will deliver NASA's largest and most capable rover to the surface of Mars. MSL will explore previously unattainable landing sites due to the implementation of a high precision Entry, Descent, and Landing (EDL) system. The parachute decelerator subsystem (PDS) is an integral prat of the EDL system, providing a mass and volume efficient some of aerodynamic drag to decelerate the entry vehicle from Mach 2 to subsonic speeds prior to final propulsive descent to the sutface. The PDS for MSL is a mortar deployed 19.7m Viking type Disk-Gap-Band (DGB) parachute; chosen to meet the EDL timeline requirements and to utilize the heritage parachute systems from Viking, Mars Pathfinder, Mars Exploration Rover, and Phoenix NASA Mars Lander Programs. The preliminary design of the parachute soft goods including materials selection, stress analysis, fabrication approach, and development testing will be discussed. The preliminary design of mortar deployment system including mortar system sizing and performance predictions, gas generator design, and development mortar testing will also be presented.

Entry, Descent, and Landing (EDL)↗

Latest Strategic Surface Metering System and Progress Status in CLT

This presentation provides description of the field evaluation of surface metering deployed by NASA in Charlotte International Airport (CLT) that began with a more tactical decision timeline and progressively expanded toward more strategic timelines. This will include an update on the latest status of the ongoing research and lessons learned.

surface metering↗

Intra-EVA Space-to-Ground Interactions when Conducting Scientific Fieldwork Under Simulated Mars Mission Constraints

The Biologic Analog Science Associated with Lava Terrains (BASALT) project is a four-year program dedicated to iteratively designing, implementing, and evaluating concepts of operations (ConOps) and supporting capabilities to enable and enhance scientific exploration for future human Mars missions. The BASALT project has incorporated three field deployments during which real (non-simulated) biological and geochemical field science have been conducted at two high-fidelity Mars analog locations under simulated Mars mission conditions, including communication delays and data transmission limitations. BASALT's primary Science objective has been to extract basaltic samples for the purpose of investigating how microbial communities and habitability correlate with the physical and geochemical characteristics of chemically altered basalt environments. Field sites include the active East Rift Zone on the Big Island of Hawai'i, reminiscent of early Mars when basaltic volcanism and interaction with water were widespread, and the dormant eastern Snake River Plain in Idaho, similar to present-day Mars where basaltic volcanism is rare and most evidence for volcano-driven hydrothermal activity is relict. BASALT's primary Science Operations objective has been to investigate exploration ConOps and capabilities that facilitate scientific return during human-robotic exploration under Mars mission constraints. Each field deployment has consisted of ten extravehicular activities (EVAs) on the volcanic flows in which crews of two extravehicular and two intravehicular crewmembers conducted the field science while communicating across time delay and under bandwidth constraints with an Earth-based Mission Support Center (MSC) comprised of expert scientists and operators. Communication latencies of 5 and 15 min one-way light time and low (0.512 Mb/s uplink, 1.54 Mb/s downlink) and high (5.0 Mb/s uplink, 10.0 Mb/s downlink) bandwidth conditions were evaluated. EVA crewmembers communicated with the MSC via voice and text messaging. They also provided scientific instrument data, still imagery, video streams from chest-mounted cameras, GPS location tracking information. The MSC monitored and reviewed incoming data from the field across delay and provided recommendations for pre-sampling and sampling tasks based on their collective expertise. The scientists used dynamic priority ranking lists, referred to as dynamic leaderboards, to track and rank candidate samples relative to one another and against the science objectives for the current EVA and the overall mission. Updates to the dynamic leaderboards throughout the EVA were relayed regularly to the IV crewmembers. The use of these leaderboards enabled the crew to track the dynamic nature of the MSC recommendations and helped minimize crew idle time (defined as time spent waiting for input from Earth during which no other productive tasks are being performed). EVA timelines were strategically designed to enable continuous (delayed) feedback from an Earth-based Science Team while simultaneously minimizing crew idle time. Such timelines are operationally advantageous, reducing transport costs by eliminating the need for crews to return to the same locations on multiple EVAs while still providing opportunities for recommendations from science experts on Earth, and scientifically advantageous by minimizing the potential for cross-contamination across sites. This paper will highlight the space-to-ground interaction results from the three BASALT field deployments, including planned versus actual EVA timeline data, ground assimilation times (defined as the amount of time available to the MSC to provide input to the crew), and idle time. Furthermore, we describe how these results vary under the different communication latency and bandwidth conditions. Together, these data will provide a basis for guiding and prioritizing capability development for future human exploration missions.

Beaton, Kara H.↗

International Space Station Satellite Deployment: Jettison Policy and Best Practices for Satellite Payload Developers

The International Space Station (ISS) deploys dozens of small satellites into Low Earth Orbit (LEO) each year. This presentation and associated paper cover the ISS Jettison Policy requirements and review/approval process, as well as best practices for satellite Payload Developers who have satellites manifested for deployment from ISS. Specifically, topics will include ISS Jettison Policy requirements to limit generation of orbital debris, limit risk of collision with ISS, and limit risk of collision with ISS visiting vehicles. The paper will include details on the ISS Program jettison candidate analysis and approval process, timelines for data submittal to ISS Program, resources for small satellite developers, and design & analysis recommendations for small satellite developers to maximize their likelihood of successful deployment from ISS. New Station deploy capabilities and ways the ISS Program addresses and facilitates innovations in small satellite technology, including propulsion systems, deorbit devices, constellation development, and novel tech demos, will also be explored. The 2024 session topic that best fits this abstract is Orbital Debris, SSA & STM. The ISS Jettison Policy intends to quantify and control the risks of deploying and operating small satellites, not only to ensure the safety of the humans flying in space, but also to preserve the orbital environment for world space activities and enable the significant benefits brought by such utilization. The ISS Program is committed to working with smallsat providers to address their challenges and enable safe, accessible, innovative missions. The Policy has grown with the industry, with each deploy yielding hard-earned lessons learned that improve our process – not only for the next deploy campaign, but with applicability and adaptability for future applications in LEO and beyond.

Jettison Policy↗

InSight Robotic Arm Testing Activities for HP3 Mole Anomaly Recovery on Mars

The InSight lander’s Heat Flow and Physical Properties Package (HP3 ) was deployed on Mars in February 2019 and began attempting to penetrate to its target depth range of 3-5 meters shortly thereafter. However, the mole’s downward progress stopped after only 35 cm of penetration. In response, the project convened an Anomaly Response Team (ART) and since then has been attempting to diagnose the problem and assist the mole using the tools available on Mars. The key asset used in this effort has been the Instrument Deployment System (IDS), which includes two cameras and a robotic Instrument Deployment Arm (IDA). Since the IDS was originally intended only to deploy InSight’s primary instruments to the Martian surface, new testbed setups, experiments, and operational protocols (e.g., command sequences) were required and had to be developed on a short timeline. The HP3 Mole ART first focused on gathering all observable data on Mars about the state of the mole and Support Structure Assembly (SSA), as well as the physical properties of the Martian regolith. This included using the robotic arm to point the IDC (Instrument Deployment Camera) at the SSA during diagnostic hammering attempts to observe motion of the SSA and science tether. Images taken during these attempts revealed some motion of the SSA, but no apparent change in mole depth. At JPL, the IDS and Testbed teams re-created the hardware configuration on Mars based on limited knowledge of the mole’s state. They devised and tested techniques to use the robotic arm and cameras to accomplish previously untested activities on Mars, including imaging the HP3 , using the IDA to interact with the terrain, and using the IDA to move the SSA away from the partially-embedded mole. The team executed the more promising techniques on Mars. After diagnostic hammering on Mars, the team decided to move the SSA to gain visibility of the mole’s configuration and access to the soil around the mole. After developing the technique and practicing the maneuver in the InSight testbed, the team lifted the SSA on Mars and placed it behind the mole. This revealed a pit surrounding the now exposed mole, observations of which provided essential clues for determining the root cause of the mole’s lack of progress. The IDS and Testbed teams altered the testbed to match the situation on Mars. They devised IDA techniques to determine the Martian soil properties and assist the mole’s descent. They tested these techniques in the testbed and executed the more promising ones on Mars. These include using the robotic arm to alter the regolith near the mole and to push on the mole while it hammers. This paper discusses the anomaly resolution testing in the testbed at JPL, describes how the IDS team prepared for the anomaly recovery activities on Mars, and provides preliminary results of the efforts to assist the HP3 mole on Mars.

Kim, Junggon↗

Mars Science Laboratory Overview and MSL EDL Challenges

An overview of Mars Science Laboratory (MSL) Entry, Descent and Landing (EDL) challenges is presented. The topics include: 1) MSL Project Overview; 2) Mars Science Laboratory Top Level Schedule (Single Launch); 3) EDL Challenges; 4) MSL Surface System; 5) Mars Rover Wheel Family Tree; 6) Gusev Comparisons; 7) Mars Surface Accessibility; 8) Atlas V 401 Launch Performance; 9) Parachute Deployment Altitude Variation with Time of Year and Latitude; 10) Dust Storms and Winds; 11) Nominal MSL EDL Timeline; and 12) Specific EDL Challenges.

Umland, Jeffrey W.↗

The Near Earth Object Scout Spacecraft: A Low Cost Approach to in-situ Characterization of the NEO Population

In this paper we describe a micro/nano satellite spacecraft and a supporting mission profile and architecture designed to enable preliminary in-situ characterization of a significant number of Near Earth Objects (NEOs) at reasonable cost. The spacecraft will be referred to as the NEO Scout. NEO Scout spacecraft are to be placed in GTO, GEO, or cis-lunar space as secondary payloads on launch vehicles headed for GTO or beyond and will begin their mission after deployment from the launcher. A distinguishing key feature of the NEO scout system is to design the mission timeline and spacecraft to rendezvous with and land on the target NEOs during close approach to the Earth-Moon system using low-thrust/high- impulse propulsion systems. Mission feasibility and preliminary design analysis are presented along with detailed trajectory calculations. The use of micro/nano satellites in low-cost interplanetary exploration is attracting increasing attention and is the subject of several annual workshops and published design studies (1-4). The NEO population consists of those asteroids and short period comets orbiting the Sun with a perihelion of 1.3 astronomical units or less (5-8). As of July 30, 2013 10065 Near-Earth objects have been discovered. The spin rate, mass, density, surface physical (especially mechanical) properties, composition, and mineralogy of the vast majority of these objects are highly uncertain and the limited available telescopic remote sensing data imply a very diverse population (5-8). In-situ measurements by robotic spacecraft are urgently needed to provide the characterization data needed to support hardware and mission design for more ambitious human and robotic NEO operations. Large numbers of NEOs move into close proximity with the Earth-Moon system every year (9). The JPL Near-Earth Object Human Space Flight Accessible Targets Study (NHATS) (10) has produced detailed mission profile and delta V requirements for various NEO missions ranging from 30 to 420 days in duration and assuming chemical propulsion. Similar studies have been reported assuming high power electric propulsion for manned NEO rendezvous missions (11). The delta V requirement breakdown and mission profile data from references 10 and 11 are used as a basis for sizing the NEO Scout spacecraft and for conducting preliminary feasibility assessments using the Tsiokolvsky rocket equation, a (worst-case) delta V requirement of 10 km/sec, and a maximum spacecraft dry mass of 20 kg. Using chemical propellant for a 10 km/sec delta V drives spacecraft wet mass well above 300 kg so that chemical propulsion is a non-starter for the proposed mission profile and spacecraft wet mass limits. In contrast, a solar electric propulsion system needs only 8 kg of Xe propellant to accelerate the spacecraft to 10 km/sec in 163 days with 0.02 N of thrust and 500 W of power from1.6 sq m of 29% efficient solar panels. In a second example, accelerating a 4 kg payload to 7 km/sec over 180 days requires about 6.7 kg of propellant and 1.2 kg of solar panels (12 kg total spacecraft wet mass).

Koontz, Steven L.↗

IUS/TUG orbital operations and mission support study. Volume 3: Space tug operations

A study was conducted to develop space tug operational concepts and baseline operations plan, and to provide cost estimates for space tug operations. Background data and study results are presented along with a transition phase analysis (the transition from interim upper state to tug operations). A summary is given of the tug operational and interface requirements with emphasis on the on-orbit checkout requirements, external interface operational requirements, safety requirements, and system operational interface requirements. Other topics discussed include reference missions baselined for the tug and details for the mission functional flows and timelines derived for the tug mission, tug subsystems, tug on-orbit operations prior to the tug first burn, spacecraft deployment and retrieval by the tug, operations centers, mission planning, potential problem areas, and cost data.

Source record↗

Web Application Software for Ground Operations Planning Database (GOPDb) Management

A Web application facilitates collaborative development of the ground operations planning document. This will reduce costs and development time for new programs by incorporating the data governance, access control, and revision tracking of the ground operations planning data. Ground Operations Planning requires the creation and maintenance of detailed timelines and documentation. The GOPDb Web application was created using state-of-the-art Web 2.0 technologies, and was deployed as SaaS (Software as a Service), with an emphasis on data governance and security needs. Application access is managed using two-factor authentication, with data write permissions tied to user roles and responsibilities. Multiple instances of the application can be deployed on a Web server to meet the robust needs for multiple, future programs with minimal additional cost. This innovation features high availability and scalability, with no additional software that needs to be bought or installed. For data governance and security (data quality, management, business process management, and risk management for data handling), the software uses NAMS. No local copy/cloning of data is permitted. Data change log/tracking is addressed, as well as collaboration, work flow, and process standardization. The software provides on-line documentation and detailed Web-based help. There are multiple ways that this software can be deployed on a Web server to meet ground operations planning needs for future programs. The software could be used to support commercial crew ground operations planning, as well as commercial payload/satellite ground operations planning. The application source code and database schema are owned by NASA.

Lanham, Clifton↗

The Near Earth Object (NEO) Scout Spacecraft: A Low-cost Approach to In-situ Characterization of the NEO Population

This paper describes a microsatellite spacecraft with supporting mission profile and architecture, designed to enable preliminary in-situ characterization of a significant number of Near Earth Objects (NEOs) at reasonably low cost. The spacecraft will be referred to as the NEO-Scout. NEO-Scout spacecraft are to be placed in Geosynchronous Equatorial Orbit (GEO), cis-lunar space, or on earth escape trajectories as secondary payloads on launch vehicles headed for GEO or beyond, and will begin their mission after deployment from the launcher. A distinguishing key feature of the NEO-Scout system is to design the spacecraft and mission timeline so as to enable rendezvous with and landing on the target NEO during NEO close approach (<0.3 AU) to the Earth-Moon system using low-thrust/high-impulse propulsion systems. Mission durations are on the order 100 to 400 days. Mission feasibility and preliminary design analysis are presented, along with detailed trajectory calculations.

Woeppel, Eric A.↗

The Lucy Spacecraft

The Lucy spacecraft is developed from a combination of heritage components used on other NASA deep space missions, combined with a set of newly developed hardware specific to Lucy’s mission, most critically the solar arrays. These components are configured into a spacecraft capable of launching on the least expensive Atlas launch vehicle, deploying into a power-safe configuration, executing the high-precision Trojan asteroid encounters, and surviving the 12-year mission timeline.

planetary↗

Autonomy @NASA

NASA's work in deploying autonomy technologies to improve aeronautics and space missions over the last 25 years. Widely disseminated examples are highlighted, mostly in a few timeline charts, but with a few specific examples.

Van Dalsem, William R.↗

The Big Plunge at Venus: The DAVINCI Descent Phase

DAVINCI (Deep Atmosphere Venus Investigation of Noble gases, Chemistry, and Imaging) was selected as one of two new Discovery missions in summer of 2021 with the primary goals to study how the Venus atmosphere formed and changed over time. DAVINCI does this by making in situ measurements of the atmosphere, taking images below the cloud layer during the descent phase, and imaging the surface and clouds during two flyby science opportunities. The Descent Sphere is neither designed nor required to land on the surface so all critical science data must be taken and transmitted to a relay spacecraft prior to impact. This architecture drives the mission to a carefully-crafted concept of operations; deployments, instrument operations, and communications are choreographed to ensure the right data is gathered at the right altitude given the uncertainties in the trajectory and timeline. A complex flow of analyses and tests throughout development will validate the system’s ability to execute the mission goals. In the end DAVINCI will be ready for its one hour of descent time to meet its driving science goals.

DAVINCI↗

The Big Plunge at Venus: The DAVINCI Descent Phase

DAVINCI (Deep Atmosphere Venus Investigation of Noble gases, Chemistry, and Imaging) was selected as one of two new Discovery missions in summer of 2021 with the primary goals are to study how the Venus atmosphere formed and changed over time. DAVINCI does this by making in situ measurements of the atmosphere and taking images below the cloud layer during the descent phase. The probe is neither designed nor required to land on the surface so all critical science data must be taken and transmitted to a relay spacecraft prior to impact. This architecture drives the mission to a carefully-crafted concept of operations; deployments, instrument operations, and communications are choreographed to ensure the right data is gathered at the right altitude given the uncertainties in the trajectory and timeline. A complex flow of analyses and tests throughout development will validate the system’s ability to execute the mission goals. In the end, DAVINCI will be ready for the one opportunity at one hour of descent time to meet its driving science goals.

DAVINCI↗

InSight Robotic Arm Testing Activities for HP3 Mole Anomaly Recovery on Mars

The InSight lander’s Heat Flow and Physical Properties Package (HP3) was deployed on Mars in February 2019and began attempting to penetrate to its target depth range of3-5 meters shortly thereafter. However, the mole’s downwardprogress stopped after only 35 cm of penetration. In response,the project convened an Anomaly Response Team (ART) andsince then has been attempting to diagnose the problem andassist the mole using the tools available on Mars. The key assetused in this effort has been the Instrument Deployment System(IDS), which includes two cameras and a robotic InstrumentDeployment Arm (IDA). Since the IDS was originally intendedonly to deploy InSight’s primary instruments to the Martiansurface, new testbed setups, experiments, and operational protocols (e.g., command sequences) were required and had to bedeveloped on a short timeline. The HP3 Mole ART first focusedon gathering all observable data on Mars about the state ofthe mole and Support Structure Assembly (SSA), as well asthe physical properties of the Martian regolith. This includedusing the robotic arm to point the IDC at the SSA duringdiagnostic hammering attempts to observe motion of the SSAand science tether. Images taken during these attempts revealedsome motion of the SSA, but no apparent change in mole depth.At JPL, the IDS and Testbed teams re-created the hardwareconfiguration on Mars based on limited knowledge of the mole’sstate. They devised and tested techniques to use the roboticarm and cameras to accomplish previously untested activitieson Mars, including imaging the HP3, using the IDA to interactwith the terrain, and using the IDA to move the SSA awayfrom the partially-embedded mole. The team executed the morepromising techniques on Mars. After diagnostic hammering onMars, the team decided to move the SSA to gain visibility ofthe mole’s configuration and access to the soil around the mole.After developing the technique and practicing the maneuver inthe InSight testbed, the team lifted the SSA on Mars and placedit behind the mole. This revealed a pit surrounding the nowexposed mole, observations of which provided essential cluesfor determining the root cause of the mole’s lack of progress.The IDS and Testbed teams altered the testbed to match thesituation on Mars. They devised IDA techniques to determinethe Martian soil properties and assist the mole’s descent. Theytested these techniques in the testbed and executed the more978-1-7281-2734-7/20/$31.00 c 2021 IEEE. Copyright 2020 CaliforniaInstitute of Technology. U.S. Government sponsorship acknowledged.promising ones on Mars. These include using the robotic arm toalter the regolith near the mole and to push on the mole while ithammers. This paper discusses the anomaly resolution testing inthe testbed at JPL, describes how the IDS team prepared for theanomaly recovery activities on Mars, and provides preliminaryresults of the efforts to assist the HP3 mole on Mars.

Kim, Junggon↗