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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 487 records · Page 27
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Heat Exchanger Intensification Through Powder Processing and Enhanced Design (HIPPED)

High intensity, supercritical CO 2 heat exchangers capable of operating at temperatures between 800 and 1100 ˚C and pressures greater than 80 bar are considered a critical component for high efficiency power generation and a range of next-generation industrial processes. A novel heat exchanger concept was proposed in this project. The proposed concept involved a plate-type architecture with three-dimensional fins, called twisted s-shaped fins, that capitalize on additive manufacturing. Four manufacturing processes were studied to realize the complex envisioned design: press and sinter of metallic powders, directed energy deposition, laser powder bed fusion, and a novel powder bed process involving a photoreactive polymer called SEAM (scalable expeditious additive manufacturing), that later was developed at MSU. The team was able to manufacture subscale heat exchangers using laser powder bed fusion (LPBF) and SEAM. The team settled on using SEAM as a final manufacturing approach due to its very low cost. The SEAM-manufactured heat exchanger, however, when tested under pressure, exhibited leaks and the process still requires further development beyond the timeline of the project. To support the heat exchanger design and testing, the team developed a new high temperature flow loop allowing testing under high temperature and pressure. Computational modeling of the heat exchanger was also performed for the twisted s-shaped fins and the computations were validated with experimental data. The new twisted fins resulted in enhanced heat transfer and reduced pressure drop. To further minimize pressure drop in the plate heat exchanger, the team also developed a simplified model for flow maldistribution in the manifolds, providing a new tool for designers that eliminates the need for complex CFD calculations. A technoeconomic analysis was also developed to contrast SEAM with LPBF, this tool indicated that SEAM is several times less costly and offer significant promises as a rapid low cost additive manufacturing process for metallic systems.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2014

Final Report for Project "Framework Application for Core-Edge Transport Simulations (FACETS)"

This is the final report for the Colorado State University Component of the FACETS Project. FACETS was focused on the development of a multiphysics, parallel framework application that could provide the capability to enable whole-device fusion reactor modeling and, in the process, the development of the modeling infrastructure and computational understanding needed for ITER. It was intended that FACETS be highly flexible, through the use of modern computational methods, including component technology and object oriented design, to facilitate switching from one model to another for a given aspect of the physics, and making it possible to use simplified models for rapid turnaround or high-fidelity models that will take advantage of the largest supercomputer hardware. FACETS was designed in a heterogeneous parallel context, where different parts of the application can take advantage through parallelism based on task farming, domain decomposition, and/or pipelining as needed and applicable. As with all fusion simulations, an integral part of the FACETS project was treatment of the coupling of different physical processes at different scales interacting closely. A primary example for the FACETS project is the coupling of existing core and edge simulations, with the transport and wall interactions described by reduced models. However, core and edge simulations themselves involve significant coupling of different processes with large scale differences. Numerical treatment of coupling is impacted by a number of factors including, scale differences, form of information transferred between processes, implementation of solvers for different codes, and high performance computing concerns. Operator decomposition involving the computation of the individual processes individually using appropriate simulation codes and then linking/synchronizing the component simulations at regular points in space and time, is the defacto approach to high performance simulation of multiphysics, multiscale systems. Various forms of operator decomposition are used in nearly all fusion simulations. However, operator decomposition generally has a complex effect on accuracy and stability of numerical simulations. Yet, these effects can be difficult to detect. The Colorado State University component of the FACETS team led by P.I.D. Estep was focused on analyzing the effects of operator decomposition on fusion simulations. The approach was based on a posteriori error analysis employing adjoint problems, computable residuals, and variational analysis to produce accurate computational error estimates for quantities of interest. Computable residuals are used to quantify the effects of various discretization choices. The generalized Greens function satisfying the adjoint problem quantities the effects of stability. Technical issues to be addressed included: (1) defining appropriate adjoint operators for operator decomposition discretizations; (2) determining the appropriate residuals for the multifaceted aspects involved with multiphysics discretizations; (3) producing the estimates within the computational framework of existing fusion codes; (4) carrying out the analysis for discretizations used in fusion simulations; and (5) devising efficient approaches to mitigating the effects of discretization. This report provides a summary of the accomplished research and a detailed description of personnel, activities, outcomes and achievements.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
NASA NTRS1999

SIRTF Science Operations System Design

SIRTF Science Operations System Design William B. Green Manager, SIRTF Science Center California Institute of Technology M/S 310-6 1200 E. California Blvd., Pasadena CA 91125 (626) 395 8572 Fax (626) 568 0673 bgreen@ipac.caltech.edu. The Space Infrared Telescope Facility (SIRTF) will be launched in December 2001, and perform an extended series of science observations at wavelengths ranging from 20 to 160 microns for five years or more. The California Institute of Technology has been selected as the home for the SIRTF Science Center (SSC). The SSC will be responsible for evaluating and selecting observation proposals, providing technical support to the science community, performing mission planning and science observation scheduling activities, instrument calibration during operations and instrument health monitoring, production of archival quality data products, and management of science research grants. The science payload consists of three instruments delivered by instrument Principal Investigators located at University of Arizona, Cornell, and Harvard Smithsonian Astrophysical Observatory. The SSC is responsible for design, development, and operation of the Science Operations System (SOS) which will support the functions assigned to the SSC by NASA. The SIRTF spacecraft, mission profile, and science instrument design have undergone almost ten years of refinement. SIRTF development and operations activities are highly cost constrained. The cost constraints have impacted the design of the SOS in several ways. The Science Operations System has been designed to incorporate a set of efficient, easy to use tools which will make it possible for scientists to propose observation sequences in a rapid and automated manner. The use of highly automated tools for requesting observations will simplify the long range observatory scheduling process, and the short term scheduling of science observations. Pipeline data processing will be highly automated and data-driven, utilizing a variety of tools developed at JPL, the instrument development teams, and Space Telescope Science Institute to automate processing. An incremental ground data system development approach has been adopted, featuring periodic deliveries that are validated with the flight hardware throughout the various phases of system level development and testing. This approach minimizes development time and decreases operations risk. This paper will describe the top level architecture of the SOS and the basic design concepts. A summary of the incremental development approach will be presented. Examples of the unique science user tools now under final development prior to the first proposal call scheduled for mid-2000 will be shown.

Green, William↗
DOE OSTI2026

High-Speed Layup and Forming of Automotive Composite Components

This Project is focused on the design and manufacture of automotive components that meet functional and environmental requirements of an existing automotive application at a cost of ≤ $\$$11.00 per kilogram weight reduction. This project fosters the development of composite material technologies suitable for high volume automotive processes and run rates as well as industry workforce development with these technologies. Current automotive manufacturing involves utilizing steel or aluminum in sheet form which is rapidly stamped into components at rates up to 3600 per hour. The metallic sheets are available in many different thicknesses, strength levels, and manufacturing rates are reasonable independent of part size. While composite materials are available for use in automotive applications, the material cost, labor to manufacture and the processing of the waste far exceed the cost compared to metallic designs. Typical composite layer by layer layup procedures don’t meet the desired 60 second layup time that current automotive processes require and are also restricted by part size. Due to these factors, composites have not yet made advances into today’s high volume automotive applications. Industry partners DURA, BASF, Ford, and IACMI core innovation partner MSU collaborated to develop a manufacturing process technology that is capable of manufacturing composite blanks at high volume and independent of part size. IACMI core innovation partner Purdue provided FEA analysis and cost modelling. The objective of this project was to demonstrate a composite sheet layup and consolidation process that can be commercialized for high volume requirements, identify potential layup equipment suppliers, and develop a process of 60 second layup, forming, and trimming of a continuous fiber automotive component for the mainstream market.

42 ENGINEERING↗
NASA NTRS1994

Toward Real Time Neural Net Flight Controllers

NASA Ames Research Center has an ongoing program in neural network control technology targeted toward real time flight demonstrations using a modified F-15 which permits direct inner loop control of actuators, rapid switching between alternative control designs, and substitutable processors. An important part of this program is the ACTIVE flight project which is examining the feasibility of using neural networks in the design, control, and system identification of new aircraft prototypes. This paper discusses two research applications initiated with this objective in mind: utilization of neural networks for wind tunnel aircraft model identification and rapid learning algorithms for on line reconfiguration and control. The first application involves the identification of aerodynamic flight characteristics from analysis of wind tunnel test data. This identification is important in the early stages of aircraft design because complete specification of control architecture's may not be possible even though concept models at varying scales are available for aerodynamic wind tunnel testing. Testing of this type is often a long and expensive process involving measurement of aircraft lift, drag, and moment of inertia at varying angles of attack and control surface configurations. This information in turn can be used in the design of the flight control systems by applying the derived lookup tables to generate piece wise linearized controllers. Thus, reduced costs in tunnel test times and the rapid transfer of wind tunnel insights into prototype controllers becomes an important factor in more efficient generation and testing of new flight systems. NASA Ames Research Center is successfully applying modular neural networks as one way of anticipating small scale aircraft model performances prior to testing, thus reducing the number of in tunnel test hours and potentially, the number of intermediate scaled models required for estimation of surface flow effects.

Jorgensen, C. C.↗
DOE OSTI2021

Method for Rapid Modeling of Distortion in Laser Powder Bed Fusion Metal Additive Manufacturing Parts

The simulation and modeling of part-level distortion and residual stress in diverse metal additive manufacturing (AM) geometries has great potential to enable the rapid adoption of this technology in engineering design. Moreover, the use of additive manufacturing component libraries (CLs) offer a computationally efficient means of quantifying these part-level defects resultant from AM processing. We report on how the individual simulations of simple shapes, potential entries in a CL, can be superimposed to provide an indication of distortion and residual stresses in complex geometries. Laser powder bed fusion AM was used to construct test geometries of varied shapes and their combinations in the form of CLs in an effort to characterize location-dependent and feature-dependent distortion distributions. Blue light scanning was used to experimentally measure 3D distortions in order to investigate the interaction between the component shapes and local boundary conditions. Overall, part-level distortions were highly dependent on test component geometry, local boundary conditions, and shape combination. Commercial finite element software was used to verify experimental trends and to make predictions of distortion. The use of CLs resulted in over 20 times savings in computational cost while reproducing overall trends in distortion for test geometry assemblies. Therefore, it is anticipated that the use of CLs for L-PBF AM geometries has demonstrated potential to facilitate efficient simulations of full component AM assemblies, thereby reducing the need for costly trial-and-error-type experimental analysis.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Island scanning pattern optimization for residual deformation mitigation in laser powder bed fusion via sequential inherent strain method and sensitivity analysis

Laser powder bed fusion (L-PBF) has emerged as one of the mainstream additive manufacturing approaches for fabricating metal parts with complex geometries and intricate internal structures. However, large deformation associated with rapid heating and cooling can lead to build failure and requires post-processing which may increase manufacturing cost and prolong the production period. Here in this work, an island scanning pattern design method is proposed to optimize the scanning direction of each island in order to reduce part deformation after cutting off the build platform. The objective of this optimization is to minimize the upward bending of the part after sectioning, which allows the part deformation to satisfy the tolerance requirement or reduce the post heat treatment time. Inherent strain method is employed in the sequential finite element analysis consisting of layer-by-layer activations and sectioning for fast residual distortion prediction. Full sequential sensitivity analysis for the formulated optimization is provided to update the island scanning directions. To show the feasibility and effectiveness of the proposed method, the scanning patterns of a block structure and a connecting rod were designed and parts were fabricated using an open architecture L-PBF machine. The fabrication experiments demonstrated that the residual deformation of both parts fabricated by optimized scanning pattern can be reduced by over 50% compared to the initial scanning patterns, which demonstrate the effectiveness of the proposed method.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Atomic dynamics of gas-dependent oxide reducibility

Understanding oxide reduction is critical for advancing metal production, catalysis and energy technologies. Although carbon monoxide (CO) and hydrogen (H 2 ) are widely used reductants, the mechanisms by which they work are often presumed to be similar, both involving lattice oxygen removal. However, because of growing interest in replacing CO with H 2 to lower CO 2 emissions, distinguishing gas-specific reduction pathways is critical. Yet, capturing these atomic-scale processes under reactive gas and high-temperature conditions remains challenging. Here we use environmental transmission electron microscopy, which is capable of real-time, atomic-resolution imaging of gas–solid redox reactions to directly visualize the gas-dependent oxide reduction dynamics in NiO. We show that CO drives surface nucleation and the growth of metallic Ni islands, leading to self-limiting surface metallization. Conversely, H 2 activates a coupled surface-to-bulk transformation, where protons from dissociated H 2 infiltrate the oxide lattice to promote the inward migration of surface-generated oxygen vacancies and enabling bulk metallization. By contrast, oxygen vacancies formed by CO remain confined near the surface, where they rapidly form a metallic Ni layer that inhibits further reduction. Furthermore, these results reveal distinct atomistic pathways for CO and H 2 and provide insights that may guide metallurgical processes and catalyst design.

36 MATERIALS SCIENCE↗
DOE OSTI2015

Strong enhancement of surface diffusion by nonlinear surface acoustic waves

The phenomenon of acoustic activation of surface diffusion is investigated in a combined computational and experimental study. The ability of pulsed laser-generated surface acoustic waves (SAWs) to enhance the mobility of small atomic clusters is demonstrated by directly tracking, with fluorescence microscopy, individual Au 8 clusters moving on a (111) silicon substrate. In this work, a 19-fold increase in the effective diffusion coefficient is measured in room temperature experiments in the presence of SAWs generated by nanosecond pulse laser irradiation at a 100 Hz repetition rate. A strong enhancement of cluster mobility by SAWs is also observed in large-scale molecular dynamics simulations of surface diffusion of small atomic clusters. The analysis of the computational results demonstrates that the nonlinear sharpening of SAWs and the corresponding enrichment of the SAW spectra by high frequency harmonics which are capable of dynamic coupling to the cluster vibrations are responsible for the efficient acoustic activation of surface mobility in the simulations. The increase in the effective diffusion coefficient is proportional to the number of the SAW pulses passing through the diffusion region per unit time and a dramatic 4500-fold diffusion enhancement (corresponds to an equivalent temperature increase by ~10 3 K ) is predicted in the simulations for 15 GHz SAWs. The ability of SAWs to affect atomic-level surface processes has far-reaching implications for the design of new techniques where the acoustic energy serves as an effective substitution for thermal activation in applications where heating must be avoided or rapid switching of surface conditions is required.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2025

A Performance Model of In-Situ Techniques

The computational capacity of High-Performance Computing (HPC) systems increases continuously with the rapid development of central processing units (CPUs) and graphic processing units (GPUs), while the in-/output (IO) subsystem develops relatively slowly and storage capacity is also limited. Data-intensive applications, which are designed to leverage the high computational capacity of HPC resources, typically generate a considerable amount of data for post-processing visualizations and data analytics. The limited IO speed and storage space could lead to constraints in the actual performance of these applications and, therefore, scientific discovery. In-situ techniques, where data is visualized/analysed while still in memory rather than through disk, can contribute to alleviating these problems as they can reduce or even fully avoid data writing/reading through the IO subsystem to/from storage. However, the overall efficiency of insitu techniques crucially depends on the characteristics of both the in-situ tasks and the applications, and the resource distribution among them. Therefore, choosing the right in-situ approach (synchronous, asynchronous, or hybrid) and resource allocation is essential to minimize overhead and maximize the benefits of concurrent execution. In this paper, we present a performance model of in-situ techniques to find the most beneficial in-situ approach and the preferred resource configuration. We verify the high accuracy of our approach with over 6800 measurements and provide use cases with different applications.

Ju, Yi [Max Planck Computing and Data Facility, Ga↗
DOE OSTI2015

Accelerating Science Driven System Design With RAMP

Researchers from UC Berkeley, in collaboration with the Lawrence Berkeley National Lab, are engaged in developing an Infrastructure for Synthesis with Integrated Simulation (ISIS). The ISIS Project was a cooperative effort for “application-driven hardware design” that engages application scientists in the early parts of the hardware design process for future generation supercomputing systems. This project served to foster development of computing systems that are better tuned to the application requirements of demanding scientific applications and result in more cost-effective and efficient HPC system designs. In order to overcome long conventional design-cycle times, we leveraged reconfigurable devices to aid in the design of high-efficiency systems, including conventional multi- and many-core systems. The resulting system emulation/prototyping environment, in conjunction with the appropriate intermediate abstractions, provided both a convenient user programming experience and retained flexibility, and thus efficiency, of a reconfigurable platform. We initially targeted the Berkeley RAMP system (Research Accelerator for Multiple Processors) as that hardware emulation environment to facilitate and ultimately accelerate the iterative process of science-driven system design. Our goal was to develop and demonstrate a design methodology for domain-optimized computer system architectures. The tangible outcome is a methodology and tools for rapid prototyping and design-space exploration, leading to highly optimized and efficient HPC systems.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2018

Impact of Technology Developments on Cost and Embodied Energy of Advanced Polymer Composite Components

Within Manufacturing USA, The Institute for Advanced Composites Manufacturing Innovation, IACMI, is a partnership of industry, private and state universities, as well as federal, state, and local governments that are working together to benefit the nation’s energy and economic security. This diverse public/private partnership validates manufacturing technologies that respond to private industry’s need for faster and more cost-, material-, and energy-efficient composites manufacturing, including recycling at the end of product life. IACMI has set specific quantitative goals towards advancing the state-of-the-art in materials and manufacturing technologies for carbon fiber reinforced polymer matrix (CFRP) composites. The goals were set with respect to three targeted application areas, namely: automobiles, wind turbine blades and compressed gas storage tanks. The specific goals set for IACMI at the end of the first five years were to: (1) reduce the cost of productionized composite parts by 25%, (2) reduce the embodied energy in the production of these parts by 50%, and (3) increase recyclability of CFRP parts into useful products to 80% of the part being recycled. A baseline set of metrics representing the state-of-the-art at the start of IACMI (June 2015) were required to estimate the potential impact of the various technology development efforts towards these goals. Further, the actual impact on the baseline metrics as each project is completed needs to be quantified, considering the technology advances accomplished. These baseline cost and energy metrics are available on the IACMI website at https://iacmi.org/baseline-cost-energy. A special embodied energy estimator tool, developed by Oak Ridge National Laboratory (ORNL), is available to the public online at http://www.energytoolestimator.com/, and has been used to develop the baselines as well as evaluate impacts from completed IACMI projects. This report describes the impact of two recently completed IACMI sponsored technology projects on the baseline metrics. In the first project, titled “Thermoplastic Composites Parts Manufacturing Enabling High Volumes, Low Cost, Reduced Weight with Design Flexibility”, a highly drapable, easily recyclable thermoplastic coated, near net-shape carbon fiber fabric was developed. The thermoplastic coated tow (CT) fabric was manufactured using a rapid fabric formation (RFF) process developed for textile manufacturing. The DuPont, Fibrtec, and Purdue University team that accomplished the development of this low scrap rate carbon fiber product form selected an automobile control arm to be built in a follow-on phase of the project as a demonstrator of the benefits of this technology.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2020

Binder Jet Tooling for Automotive Lighting Industry. CRADA Final Report

The goal of this collaborative project between Oak Ridge National Laboratory’s (ORNL) Manufacturing Demonstration Facility (MDF) and Grote Industries, LLC was to develop additively manufactured tooling to produce lighting products in a production environment. The project explored the use of metal powder bed systems to rapidly manufacture moderately sized injection molding tools (less than 8” x 8” x 2”) for automotive lamps. The team designed the mold (male and female), manufactured the mold using the binder jet process, experimented with finishing processes, manufactured parts using the molds, and monitored the wear on the mold to predict life.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2025

Fabrication of 4H-SiC Low Gain Avalanche Detectors (LGADs)

Low gain avalanche detectors (LGADs) offer high temporal resolution for high energy particle detection, which is critical for next generation experiments in hadron colliders. While silicon LGADs (Si-LGADs) have rapidly matured in the last decade, research into silicon carbide (SiC) LGADs has only recently begun. By accounting for fundamental differences in material properties and fabrication processes, we present a prototype device design and process flow for 4H-SiC LGADs with etch-based isolation. Critical steps of the process flow and their results are discussed, including plasma etching, passivation, and the formation of low resistivity contacts. Electrical characterization (I-V, C-V) shows sufficient depletion of the device structure to demonstrate low-gain charge carrier multiplication.

High Energy Physics↗
NASA NTRS1981

Applications of electro-optic gratings in integrated optical signal processing devices

A variety of applications of electro-optically induced Bragg gratings in integrated optical signal processing and computation devices are shown. The gratings are easy to fabricate, operate efficiently on relatively low voltages and have design principles which are well known and reliable. The component allows a rapid and efficient interaction with an optical wave in a planar electro-optic waveguide. The operation of such gratings and their use as intensity modulators, spatial light modulators, and components in correlators and in a variety of computational units is described.

Verber, C. M.↗
NASA NTRS1987

Hollow cathode plasma source for active spacecraft charge control

A prototype plasma source spacecraft discharge device has been developed to control overall and differential spacecraft surface charging. The plasma source is based on a unique hollow cathode discharge, where the plasma generation process is contained completely within the cathode. This device can be operated on argon, krypton, or xenon and has a rapid cold start time of less than 4 s. The discharge system design includes a spacecraft-discharge/net-charge sensing circuit which provides the ability to measure the polarity, magnitude, pulse shape, and time duration of a discharging event. Ion currents of up to 325 microA and electron currents ranging from 0.02 to 6.0 A have been extracted from the device. In addition, the spacecraft discharge device successfully discharged capacitively biased plates, from as high as + or - 2500 V, to ground potential, and discharged and clamped actively biased plates at +5 V with respect to ground potential during ground simulation testing.

Deininger, William D.↗
NASA NTRS1994

A processing centre for the CNES CE-GPS experimentation

CNES is involved in a GPS (Global Positioning System) geostationary overlay experimentation. The purpose of this experimentation is to test various new techniques in order to select the optimal station synchronization method, as well as the geostationary spacecraft orbitography method. These new techniques are needed to develop the Ranging GPS Integrity Channel services. The CNES experimentation includes three transmitting/receiving ground stations (manufactured by IN-SNEC), one INMARSAT 2 C/L band transponder and a processing center named STE (Station de Traitements de l'Experimentation). Not all the techniques to be tested are implemented, but the experimental system has to include several functions; part of the future system simulation functions, such as a servo-loop function, and in particular a data collection function providing for rapid monitoring of system operation, analysis of existing ground station processes, and several weeks of data coverage for other scientific studies. This paper discusses system architecture and some criteria used in its design, as well as the monitoring function, the approach used to develop a low-cost and short-life processing center in collaboration with a CNES sub-contractor (ATTDATAID), and some results.

Suard, Norbert↗
NASA NTRS2000

NASA's Design and Development of a Field Goniometer Instrument Using Solid Works

With NASA suffering severe funding cutbacks, engineers at NASA are required to produce state-of-the-art hardware with limited personnel and financial resources. In light of these constraints, the new NASA mandate is to build better, faster and cheaper. In April of 1998, Stennis Space Center's Commercial Remote Sensing Program contracted to the Systems Engineering Division at NASA Ames Research Center to develop a device known as a Field Goniometer. A Field Goniometer is a device that measures bi-directional reflectance of a target, such as vegetation, relative to the sun and an imaging system in an aircraft or spacecraft. The device is able to provide a spectral fingerprint of the surface it is measuring in wavelengths from 350nm-2500nm using a hyperspectral imager. To accomplish this project, several obstacles had to be overcome. First, the design had to be completed in less than four months. Second, due to the complexity of the design, the use of solid modeling was highly desirable but most of the group's solid modelers were assigned to other jobs. Third, the amount of funding available from the customer was one half to one third the funding typically expended for a job of this nature. Our choices for this project were to design with standard 2-D CAD systems currently used in-house or train additional engineers on our existing solids package or purchase a new solid model package. The use of a 2D CAD system was very undesirable due to the complexity of the design. Using our existing solids modeler would have required a learning curve for our engineers that would be incompatible with our schedule. Prior to this project, a member of our design group researched the solid modeling industry and decided to purchase SolidWorks. After examining the product for ease of use, modeling capability, training time required and cost, we decided our highest probability of success would be to design with Solidworks. During the design phase, our fabrication group was able to provide input at the very early stages, which added significant benefit to the final product. Fabrication cost and schedule savings have been realized by having complex part geometries translated directly from the SolidWorks design models to Surfcam and other computer-aided manufacturing (CAM) software. This direct model translation capability optimized the fabrication processes. The end result was that we were able to successfully complete the project on time and on budget. Other advantages of using SolidWorks, as cited by the design team, include a rapid negotiation of the initial learning curve, the ability to develop solid model hardware prototypes (used to communicate the design intent to both the customer and the fabricator), and the ability to work as a team collaborating on a large, complex model. These types of tools and efforts represent our response to NASA's challenge to produce higher quality products within shorter design and fabrication times.

Turner, Mark↗