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At least 73 records · Page 4
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

3D Printing of Polyelectrolyte Complex-Integrated Photocurable Hydrogel Resins

In this study, we developed a photocurable hydrogel resin incorporating a polyelectrolyte complex (PEC) for 3D printing. Acrylamide-based monomers were formulated with varying PEC contents (0–15 wt %) in an aqueous KBr medium to fabricate patterned porous hydrogel structures. The morphology of printed hydrogels was characterized by field-emission scanning electron microscopy and energy-dispersive X-ray spectroscopy. Notably, the PEC5 and PEC10 formulations exhibited optimal thermal stability and compressive properties, attributed to the homogeneous distribution of PEC domains within the hydrogel matrix. Furthermore, dye adsorption experiments demonstrated excellent removal efficiency, highlighting the potential of PEC-containing hydrogels for environmental remediation applications, particularly in the treatment of dye-contaminated wastewater.

Yang, Jinchul [University of Tennesse Knoxville]↗
NASA NTRS2013

3D Guided Wave Motion Analysis on Laminated Composites

Ultrasonic guided waves have proved useful for structural health monitoring (SHM) and nondestructive evaluation (NDE) due to their ability to propagate long distances with less energy loss compared to bulk waves and due to their sensitivity to small defects in the structure. Analysis of actively transmitted ultrasonic signals has long been used to detect and assess damage. However, there remain many challenging tasks for guided wave based SHM due to the complexity involved with propagating guided waves, especially in the case of composite materials. The multimodal nature of the ultrasonic guided waves complicates the related damage analysis. This paper presents results from parallel 3D elastodynamic finite integration technique (EFIT) simulations used to acquire 3D wave motion in the subject laminated carbon fiber reinforced polymer composites. The acquired 3D wave motion is then analyzed by frequency-wavenumber analysis to study the wave propagation and interaction in the composite laminate. The frequency-wavenumber analysis enables the study of individual modes and visualization of mode conversion. Delamination damage has been incorporated into the EFIT model to generate "damaged" data. The potential for damage detection in laminated composites is discussed in the end.

Tian, Zhenhua↗
DOE OSTI2024

Techno‐Economic Analysis of Additively‐Manufactured Wind Turbine Blade Tips That Enable Technology Integration

The Additively‐Manufactured, System‐Integrated Tip (AMSIT) project is leveraging the flexibility of 3D printing to integrate several technologies in a wind turbine blade tip, while reducing the levelized cost of electricity (LCOE) produced. The design integration is demonstrated for a 200‐kW–scale turbine with 13‐m blades, with the outer 15% of the blade replaced with a 3D‐printed design. Aerodynamic performance is enhanced without increasing swept area through inclusion of a winglet and surface texturing, both challenging for traditional manufacturing. Longevity and durability are improved through integrated lightning and leading edge erosion protection. Increased power, reduced repair frequency, and ease of repair through blade modularity all contribute to reduced LCOE. The analysis is also extended to modern MW‐scale designs to estimate the impact of the technology at scale, demonstrating the potential to reduce LCOE significantly for modern onshore turbines, with even higher potential savings offshore.

3D printing↗
NASA NTRS2013

Crack Detection with Lamb Wave Wavenumber Analysis

In this work, we present our study of Lamb wave crack detection using wavenumber analysis. The aim is to demonstrate the application of wavenumber analysis to 3D Lamb wave data to enable damage detection. The 3D wavefields (including vx, vy and vz components) in time-space domain contain a wealth of information regarding the propagating waves in a damaged plate. For crack detection, three wavenumber analysis techniques are used: (i) two dimensional Fourier transform (2D-FT) which can transform the time-space wavefield into frequency-wavenumber representation while losing the spatial information; (ii) short space 2D-FT which can obtain the frequency-wavenumber spectra at various spatial locations, resulting in a space-frequency-wavenumber representation; (iii) local wavenumber analysis which can provide the distribution of the effective wavenumbers at different locations. All of these concepts are demonstrated through a numerical simulation example of an aluminum plate with a crack. The 3D elastodynamic finite integration technique (EFIT) was used to obtain the 3D wavefields, of which the vz (out-of-plane) wave component is compared with the experimental measurement obtained from a scanning laser Doppler vibrometer (SLDV) for verification purposes. The experimental and simulated results are found to be in close agreement. The application of wavenumber analysis on 3D EFIT simulation data shows the effectiveness of the analysis for crack detection. Keywords: : Lamb wave, crack detection, wavenumber analysis, EFIT modeling

Tian, Zhenhua↗
DOE OSTI2025

Systematic analysis of magnetic equilibrium reconstruction with eddy currents on LTX- β

Magnetic equilibrium reconstruction in the Lithium Tokamak Experiment-Beta (LTX-β) is complicated by strong eddy currents and toroidal asymmetries arising from its segmented, close-fitting conducting shell. In the earlier experiment LTX, these three-dimensional (3D) conductor effects significantly distorted diagnostic signals and challenged conventional axisymmetric reconstruction methods. In this work, we demonstrate that accurate plasma equilibria can be recovered on LTX-β by incorporating a small number of dominant eddy current modes derived from realistic conductor models. Using the open-source $\tt{TokaMaker}$ Grad–Shafranov solver, we reconstruct equilibria across a systematically selected set of LTX-β discharges and validate them against the legacy $\tt{PSI-Tri}$ hybrid 2D-3D code. Our results show that fully 2D $\tt{TokaMaker}$ reconstructions achieve significantly improved agreement with flux loop and Mirnov probe measurements, reducing total chi-squared fitting errors, especially during startup. Finally, we develop new hybrid 2D-3D $\tt{TokaMaker}$ reconstructions by integrating the $\tt{ThinCurr}$ 3D eddy current model, which we optimize for significant further reduction of chi-squared in most scenarios. These findings underscore the importance of realistic wall-current modeling in short-pulse tokamaks, and establish a physics-based reconstruction framework that is extensible to devices with complex passive structures and 3D wall interactions.

Grad–Shafranov solver↗
NASA NTRS1993

An efficient formulation of the coupled finite element-integral equation technique for solving large 3D scattering problems

It is often desirable to calculate the electromagnetic fields inside and about a complicated system of scattering bodies, as well as in their far-field region. The finite element method (FE) is well suited to solving the interior problem, but the domain has to be limited to a manageable size. At the truncation of the FE mesh one can either impose approximate (absorbing) boundary conditions or set up an integral equation (IE) for the fields scattered from the bodies. The latter approach is preferable since it results in higher accuracy. Hence, the two techniques can be successfully combined by introducing a surface that encloses the scatterers, applying a FE model to the inner volume and setting up an IE for the tangential fields components on the surface. Here the continuity of the tangential fields is used bo obtain a consistent solution. A few coupled FE-IE methods have recently appeared in the literature. The approach presented here has the advantage of using edge-based finite elements, a type of finite elements with degrees of freedom associated with edges of the mesh. Because of their properties, they are better suited than the conventional node based elements to represent electromagnetic fields, particularly when inhomogeneous regions are modeled, since the node based elements impose an unnatural continuity of all field components across boundaries of mesh elements. Additionally, our approach is well suited to handle large size problems and lends itself to code parallelization. We will discuss the salient features that make our approach very efficient from the standpoint of numerical computation, and the fields and RCS of a few objects are illustrated as examples.

Cwik, T.↗
DOE OSTI2024

One-shot omnidirectional pressure integration through matrix inversion

In this work, we present a method to perform 2D and 3D omnidirectional pressure integration from velocity measurements with a single-iteration matrix inversion approach. This work builds upon our previous work, where the rotating parallel ray approach was extended to the limit of infinite rays by taking continuous projection integrals of the ray paths and recasting the problem as an iterative matrix inversion problem. This iterative matrix equation is now 'fast-forwarded' to the 'infinity' iteration, leading to a different matrix equation that can be solved in a single step, thereby presenting the same computational complexity as the Poisson equation. We observe computational speedups of ~10 6 when compared to brute-force omnidirectional integration methods, enabling the treatment of grids of ~10 9 points and potentially even larger in a desktop setup at the time of publication. Further examination of the boundary conditions of our one-shot method shows that omnidirectional pressure integration implements a boundary condition where the boundary points are treated as interior points to the extent that information is available. Finally, we show how the method can be extended from the regular grids typical of particle image velocimetry to the unstructured meshes characteristic of particle tracking velocimetry data.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2025

Attempting to Develop the World’s Most Cost-Effective Metal 3D Printing Technology Through Industrial Adoption of a High-Temperature Electro-Magnetic Nozzle for 3D Printing and Computer Numerical Control Integration

This project aimed to make a practical system capable of sustained metal deposition in air engineered with industrial integration and controls. The Al-Ce wire feedstock was tailored with appropriate deposition and solidification properties for direct reactive interface printing (DRIP), and the goal was to integrate onto a Hybrid Manufacturing Technologies system for producing test parts without a controlled environment.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Attempting to Develop the World’s Most Cost-Effective Metal 3D Printing Technology Through Industrial Adoption of a High-Temperature Electro-Magnetic Nozzle for 3D Printing and Computer Numerical Control Integration

This project aimed to make a practical system capable of sustained metal deposition in air engineered with industrial integration and controls. The Al-Ce wire feedstock was tailored with appropriate deposition and solidification properties for direct reactive interface printing (DRIP), and the goal was to integrate onto a Hybrid Manufacturing Technologies system for producing test parts without a controlled environment.

36 MATERIALS SCIENCE↗
NASA NTRS2021

ED1: Design and Prototype of a 3D Printed Wind Tunnel Model with Integrated Force Measurement

Wind tunnel testing using conventionally manufactured force measurement systems (balances) is able to yield precise and accurate results. These balances are delicate, complex instruments. Due to the nature of this high-precision complexity, balances are expensive and time-consuming to produce. These factors can limit the design potential of the model because using conventionally manufactured balances generally means that the model is designed to accommodate balances that already exist. Ideally, engineers would be able to design a measurement system that is tailored to fit the needs of the model, rather than the other way around. The goal of this research project was to determine if it is possible to overcome these drawbacks by designing a wind tunnel model with a modifiable integrated force measurement system that leverages additive manufacturing. This was undertaken by utilizing the existing UT-63 wind tunnel balance (measurement system), integrating it with a model based on the existing AGARD-B model, and performing stress analysis to optimize the design. Due to time constraints, the result of this endeavor is currently incomplete. Continued analysis and optimization are required to have a thorough understanding of the success or failure of the attempted design. As additive manufacturing technology evolves, the ability for it to become the primary method of fabrication for sensitive measurement systems increases. This project contributes to this by providing one method for design, a framework for optimizing existing balances for additive manufacturing, and resources for performing necessary stress analysis.

Callie Ellsworth↗
DOE OSTI2025

3D-Printed mmWave Quasi-Holographic Antenna for 2-D Beamforming

This paper presents the design and manufacturing of a novel 2D-scanning antenna that integrates a 3D-printed Rotman lens with a quasi-holographic leaky-wave antenna (HLWA). The proposed design achieved beam-scanning capabilities by leveraging the beamforming of the Rotman lens and the high-gain directive properties of the quasi-HLWA. The Rotman lens (RL) enables beam steering in the elevation plane by switching between input ports. The quasi-HLWA, designed using holographic principles, achieves frequency-controlled beam scanning in the azimuth plane. The entire antenna structure was fabricated using additive manufacturing with an Ink1092 substrate and silver ink for the conductive traces. This approach provides greater control over material placement and design freedom compared to traditional methods. A 25° transmission linear substrate taper was used to ensure good impedance matching between the Rotman lens and the quasi-HLWA, allowing greater gain while maintaining a good scanning range. The experimental results validate the 2D scanning capability of the proposed antenna. The antenna system provides coverage from −54° to 54° in the elevation θ plane and −28° to 28° in the azimuth plane ϕ , with a maximum measured gain of 21.3 dBi at 28 GHz with an average radiation efficiency η=60 %. The fabricated prototype was tested, and the performance was in good agreement with the simulated performance.

Rotman lens↗
DOE OSTI2026

RCSB protein data Bank: Next‐generation advanced search for exploration of experimental structures and computed structure models

Abstract The Protein Data Bank (PDB), established in 1971, is the primary global, open‐access archive for experimentally determined 3D macromolecular structures (proteins, RNA, DNA). The research‐focused RCSB.org web‐portal provides access to these data alongside more than one million machine‐learning‐predicted structure models, greatly expanding the available structural landscape. Rapid growth of both experimental and computational structures has increased the need for powerful yet accessible search tools that serve a broad and diverse scientific community. Herein, we describe a redesigned RCSB Protein Data Bank RCSB.org Advanced Search capability that supports intuitive discovery of 3D structures through a unified interface. This interface integrates annotation‐, sequence‐, and 3D structure‐based searches, embeds an interactive 3D viewer, and incorporates curated biological knowledge, such as catalytic site definitions from Mechanism and Catalytic Site Atlas and ligand‐guided structural motifs, for constructing geometry‐driven queries. A new Chemical Search tool allows definition of chemical queries via an integrated drawing tool or standard identifiers, seamlessly combining them with annotation filters. By allowing query definition directly within spatial and chemical contexts, these search interfaces reduce the need for detailed knowledge of residue numbering, chain identifiers, or external cheminformatics software. This capability enables efficient exploration of structures, chemical diversity, and structure–function relationships across all life domains. The redesigned interfaces can be accessed directly at rcsb.org/search/advanced for Advanced Search and rcsb.org/search/chemical for Chemical Search.

Rose, Yana [Research Collaboratory for Structural ↗
NASA NTRS2000

Effects of Geometric Azimuthal Asymmetries of the PPM Stack on Electron Beam Characteristics

The effects of geometric azimuthally asymmetric properties of a periodic permanent magnet (PPM) focusing stack on electron beam characteristics obtained using a fully three dimensional (3D) particle-in-cell (PIC) code will be presented. The simulation model, using MAFIA (Solution of MAxwell's equations by the Finite-Integration-Algorithm), incorporates 3D behavior of the beam immersed in static fields calculated directly from the exact geometry and material properties of the 3D magnetic focusing structure. The Hughes 8916H, 18-40 GHz helical TWT for the millimeter-wave power module (MMPM) was used as a prototype. Firstly, the effects of C-magnets used at the input and output of the TWT to allow for coupling of the RF signal into and out of the tube are considered. The 8916H input and output C-magnets differ because coaxial couplers are used at the input and waveguide couplers are used at the output The repositioning of the beam from its central axis due to the inclusion of the output C-magnet was found to be most significant. The modeled output C-magnet and its orientation in the Cartesian coordinate system is shown, and a two-dimensional beam profile including the output C-magnet is also shown. A table presents the shift of the beam center off the central axis relative to the average radius of the beam at the longitudinal points A, B and C designated on an enclosed figure. Secondly, the addition of shunts, or rectangular iron pieces applied manually by a skilled technician in order to improve beam transmission, is considered. The shunts are applied to the top of the tube; thus, azimuthal symmetry of the focusing stack is interrupted. Although shunts are typically added during RF focusing, they are also typically added at the input section of the tube where RF forces are minimal, making an electron optics analysis meaningful. Because several shunts are usually applied to one pole piece, the simulations have been simplified by modeling a half washer with the same radius and longitudinal length as a shunt over the entire x, positive-y half of the transverse plane. A modeled pole piece and shunt as described are shown. Lastly, in order to study the effects of magnet misalignments, a magnet in the PPM stack was arbitrarily chosen and adjusted so that its central axis was shifted both 0.7 percent and 1.0 percent of the magnet outer diameter in the positive-y direction. In practice, positioning the magnets so that their central axis is accurately aligned with the central axis of the tube is challenging. Thus, it is a strong possibility that one or more magnets will be misaligned relative to the tube central axis.

Kory, Carol L.↗
NASA NTRS1992

Verification of effective thicknesses for side-grooved compact specimens

The definition of effective thicknesses of the ASTM standard 25 percent side-grooved compact specimens to calculate the elastic compliance, elastic SIF, and elastic-plastic J integral is reevaluated. 3D elastic-plastic analyses of polane-strain, smooth, and 25 percent side-grooved compact specimen models are conducted using the ZIP3D code. Calculated compliance, SIFs, and J-integrals are compared with E-813 solutions.

Shivakumar, Kunigal N.↗
NASA NTRS2009

Evaluation methodology guidance for stack packages

This report provides evaluation methodology guidance based on previous National Aeronautics and Space Administration (NASA) reports and literature surveys for 3D stack packages and assemblies. Two aspects of technology are covered: the package itself (guidance for functional packages) and package assembly manufacturing and reliability. This work was funded by the NASA Electronic Parts and Packaging (NEPP) Program. The objectives of this NEPP project are to: Perform a literature survey of 3D stack technology; perform a literature survey on the evaluation methodology for 3D package and assembly; combine the two aspects to provide evaluation methodology for both aspects with consideration of interactions between package and assembly; generate guidance on the evaluation methodology for 3D stack package integrity prior to and after assembly; provide recommendations on future experimental activities. The qualification and evaluation methodology guidelines will facilitate NASA projects in effectively evaluating the reliability of very dense and newly available high-density 3D stack packages, allowing more processing power in a smaller board footprint and lower system weight.

Gerke, David↗
NASA NTRS2012

Microcracking in Composite Laminates: Simulation of Crack-Induced Ultrasound Attenuation

Microcracking in composite laminates is a known precursor to the growth of inter-ply delaminations and larger scale damage. Microcracking can lead to the attenuation of ultrasonic waves due to the crack-induced scattering. 3D elastodynamic finite integration technique (EFIT) has been implemented to explore the scattering of ultrasonic waves due to microcracks in anisotropic composite laminates. X-ray microfocus computed tomography data was directly input into the EFIT simulation for these purposes. The validated anisotropic 3D EFIT code is shown to be a useful tool for exploring the complex multiple-scattering which arises from extensive microcracking.

Leckey, C. A. C.↗
DOE OSTI2025

Advancing 3D surface imaging: single-axis structured light illumination plenoptic camera with machine learning integration

Structured light illumination (SLI) is a configurable 3D surface imaging modality that can function largely independently of surface texture. At the same time, machine learning (ML) approaches are providing new ways to capture relevant information from SLI patterns, avoiding the need to develop advanced computer vision algorithms. By projecting an optical pattern onto a surface and measuring the apparent distortion of that pattern, one can determine surface topography from a single image. Common realizations of SLI 3D imaging use off-axis SLI to allow for parallax-based determination of depth; however, in constrained geometries, the ability to make single-axis measurements can be of major benefit. While plenoptic imaging (PI) cameras have long been developed for the purpose of single-axis 3D imaging, they are generally reliant on the surface texture of the measured object, thus making them unreliable in certain experimental conditions. Therefore, we present a single-axis 3D SLI plenoptic camera, which combines the single-axis benefits of PI technology while using coaxial SLI to maintain indifference to surface conditions. We also present a study of the camera capabilities paired with the development of several algorithms, including traditional feature tracking methods as well as ML methods, which are found to enhance resolution and range. We report depth sensitivity down to 0.2% $\frac{dz}{z_0}$. The single-axis SLI 3D plenoptic camera demonstrates potential applicability for in-situ topographical measurements under a wide range of conditions including, but not limited to, objects without trackable surface texture, high temperatures, and constrained geometry environments.

Imaging systems↗