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NASA NTRS2019

NASA Centennial Challenge: 3D Printed Habitat, Phase 3 Final Results

NASA's Centennial Challenges program uses prize competitions with the goal of accelerating innovation in the aerospace industry. Competitions in the Centennial Challenges portfolio have previously focused on advancements in space robotics, regolith excavation, bio-printing, astronaut suit design, small satellites, and solar-powered vehicles. NASA's Three Dimensional (3D) Printed Habitat Centennial Challenge represents a partnership between NASA and the non-profit partner: Bradley University, with co-sponsors Caterpillar, Bechtel, Brick and Mortar Ventures, the American Concrete Institute, and the United States Army Corps of Engineers (USACE) Engineer Research and Development Center (ERDC) to spur development in automated additive construction technologies. The challenge asks teams to design and construct a scaled and simulated Martian habitat using indigenous materials and large scale 3D automated printing systems. Phase 1 of the competition, held in 2015, was an architectural design competition for habitat concepts that could be 3D printed. Phase 2, completed in 2017, asked teams to develop feedstocks from indigenous materials and hydrocarbon polymer recyclables, and demonstrate automated printing systems to manufacture these feedstocks into test specimens to assess mechanical strength. This paper will discuss the Phase 3 competition, focusing on technology outcomes that can potentially be infused into both terrestrial and planetary construction applications. The Phase 3 competition was divided into two sub-competitions: 1) virtual construction, where teams created a high fidelity building information model (BIM) of their 3D-printed habitat design and 2) the construction competition, which required teams to 3D print a structural foundation and subject materials samples to freeze/thaw testing and impact testing (level 1), produce a habitat element and complete a hydrostatic test (level 2), and additively manufacture a 1:3 scale habitat onsite in a head to head competition at Caterpillar, inc.'s Edwards Demonstration & Learning Center near Peoria, Illinois over the course of three days (level 3). While the Phase 2 competition focused primarily on the development of novel feedstocks and robotic printing systems, Phase 3 emphasized the scale-up of these systems and autonomous operation (demonstrating the capability to operate systems on precursor missions prior to the arrival of crew, or terrestrially in field operation settings where human tending of a manufacturing system may be limited). The Phase 3 virtual construction levels yielded a number of novel habitat designs, including both modular habitats and vertically-oriented habitat concepts. The Phase 3 construction competition also challenged teams to autonomously place penetrations and interfacing elements in additively manufactured structures. The paper will emphasize potential applications for the new materials and technologies developed under the umbrella of the competition within NASA's portfolio and in Earth-based applications such as disaster response and infrastructure improvement.

Construction↗
NASA NTRS2019

Nasa Centennial Challenge: Three Dimensional (3d) Printed Habitat, Phase 3

NASA's Centennial Challenges program uses prize competitions with the goal of accelerating innovation in the aerospace industry. Competitions in the Centennial Challenges portfolio have previously focused on advancements in space robotics, regolith excavation, bio-printing, astronaut suit design, small satellites, and solar-powered vehicles. NASA's Three Dimensional (3D) Printed Habitat Centennial Challenge represents a partnership between NASA and the non-profit partner: Bradley University, with co-sponsors Caterpillar, Bechtel, Brick and Mortar Ventures, the American Concrete Institute, and the United States Army Corps of Engineers (USACE) Engineer Research and Development Center (ERDC) to spur development in automated additive construction technologies. The challenge asks teams to design and construct a scaled and simulated Martian habitat using indigenous materials and large scale 3D automated printing systems. Phase 1 of the competition, held in 2015, was an architectural design competition for habitat concepts that could be 3D printed. Phase 2, completed in 2017, asked teams to develop feedstocks from indigenous materials and hydrocarbon polymer recyclables, and demonstrate automated printing systems to manufacture these feedstocks into test specimens to assess mechanical strength. This paper will discuss the Phase 3 competition, focusing on technology outcomes that can potentially be infused into both terrestrial and planetary construction applications. The Phase 3 competition was divided into two sub-competitions: 1) virtual construction, where teams created a high fidelity building information model (BIM) of their 3D-printed habitat design and 2) the construction competition, which required teams to 3D print a structural foundation and subject materials samples to freeze/thaw testing and impact testing (level 1), produce a habitat element and complete a hydrostatic test (level 2), and additively manufacture a 1:3 scale habitat onsite in a head to head competition at Caterpillar, inc.'s Edwards Demonstration & Learning Center near Peoria, Illinois over the course of three days (level 3). While the Phase 2 competition focused primarily on the development of novel feedstocks and robotic printing systems, Phase 3 emphasized the scale-up of these systems and autonomous operation (demonstrating the capability to operate systems on precursor missions prior to the arrival of crew, or terrestrially in field operation settings where human tending of a manufacturing system may be limited). The Phase 3 virtual construction levels yielded a number of novel habitat designs, including both modular habitats and vertically-oriented habitat concepts. The Phase 3 construction competition also challenged teams to autonomously place penetrations and interfacing elements in additively manufactured structures. The paper will emphasize potential applications for the new materials and technologies developed under the umbrella of the competition within NASA's portfolio and in Earth-based applications such as disaster response and infrastructure improvement.

Centennial challenge↗
NASA NTRS2018

Bistable Collapsible Tubular Mast Booms

A promising candidate for deployable composite structures is the two-shelled Collapsible Tubular Mast (CTM) boom, which is to be employed on future solar sail and interplanetary small satellite platforms by the National Aeronautics and Space Administration (NASA). This is due to its two omega-shaped shells forming a closed-section which yields large stiffnesses that allowed for high dimensional stability. An inextensional analytical model describing the bending deformation mechanics of CTM booms was used to determine how design variables induce bistability, or the existence of two strain energy wells. Bistable booms were favorable due to low strain energy requirements for the coiled state and had more controllable deployment when compared to monostable booms. The effects of varying lamina material, laminate layup, and shell arc geometries between different inner and outer shell segments on the second strain energy well and stiffness properties were determined for cross-sections formed by circular segments. The full design space for two-shelled composite CTM booms was explored to evaluate the validity of the simple analytical model developed. Optimal CTM boom designs were manufactured and experimentally characterized for comparisons against model results. The model under-predicted the second stable coiled diameter of the complete two-shelled booms by 27-33% and as low as 3-8% for the individual shells wrapped alone.

Fernandez, Juan M.↗
NASA NTRSDate not supplied

Milli-Arcsecond (MAS) Imaging with SmallSat Enabled Super-resolution

The objective of this project is to demonstrate a new imaging technology with unprecedented capabilities for scientific exploration. This technology innovation will enable extremely high-resolution imaging capability, otherwise unattainable with conventional approaches. It is based on a unique combination of novel diffractive optical sensing (photon sieve), advanced image processing, and small satellite formation flying. The spatial resolution of current solar instruments are more than 100 times coarser than the size of energy dissipation features in coronal heating (<100 km) since conventional optics cannot be figured to near diffraction-limited accuracy at extreme ultraviolet (EUV) wavelengths. This project will demonstrate the feasibility of imaging of a few milli-arcseconds (MAS) to study the structure and development of these dissipation regions.

Farzad Kamalabadi↗
NASA NTRS2020

Small Business Launches Down-to-Earth Products via NASA SBIR Program

Through the SBIR program, DSSP developed a multi-pulse solid rocket motor for NASA that will enable stabilized interplanetary flight for small satellites. Another of DSSP’s core innovations with roots in the SBIR program is already having an even greater impact. Originally proposed to fuel a microsatellite thruster for Earth-observation missions, DSSP’s HAN-based green electric monopropellants (GEM and AF-M315E) technology is powering larger satellites, enhancing downhole oil and gas recovery, and much more. Highly insensitive to ignition by spark, flame, or shock, GEM-based innovations are stable, non-toxic, and more controllable than conventional propellants.

Bruce R Cogan↗
NASA NTRS2020

Experimental Investigation of Drag Modulation Aerocapture: Drag-Skirt Separation in Hypersonic Free Flight

Free flight tests were conducted in carbon dioxide at Mach 12 of notional drag modulation aerocapture configurations for a small satellite mission to Venus. The configurations were based on research conducted at the Georgia Institute of Technology, University of Colorado Boulder, Jet Propulsion Laboratory, and Ames Research Center. The drag modulation aerocapture approach being studied involves an atmospheric entry vehicle that employs an attached drag device, a drag skirt, that is jettisoned at the appropriate time to allow the payload-portion of the vehicle to exit the atmosphere, slowed enough to be captured into orbit. A total of eight tests were performed. Reynolds numbers, based on the pre-separation base diameter, ranged from 0.82 x 106 to 2.96 x 106. The tests demonstrated the feasibility of a clean drag skirt separation at hypersonic speeds and, for the conditions of the tests, the stability of the central flight system body during and after separation from the drag skirt. Two drag skirt geometries were tested: an axisymmetric conical frustum, and a faceted frustum representative of a mechanically-deployable device. Drag skirts of various masses were tested to examine the effect of pre- and post-separation ballistic coefficient ratio on the separation dynamics. A new test capability for multi-body interactions in hypersonic free flight was developed for these tests, and is described.

aerocapture↗
NASA NTRSDate not supplied

A New Concurrent Engineering Tool for the New Mission Design Center at NASA Ames Research Center

The NASA Ames Mission Design Center (MDC) has undergone a significant transformation process in recent years, culminating in becoming a true Concurrent Engineering Center. The underlying goal of this transformation is to better serve the Ames PI community in a cost-effective and rapidly-responsive way, providing quality products pivotal to the decision-making proposal strategy of our center. The four pillars of the change focus on four areas: personnel, physical places, tools, and training. Personnel: the MDC switched from using a dedicated pool of engineers—mostly entry-level career—for a matrixed approach with more experienced Subject Matter Experts, usually involved in spaceflight projects. These SMEs get detailed to the MDC for the duration of the study on a part-time or full-time basis. Physical places: The physical aspect pertains mostly to the layout of the new Engineering building and the dedicated concurrent engineering layout to foster collaboration. The current plan includes a dedicated space for concurrent engineering sessions as well as dedicated project rooms for concept studies. Tool: the MDC team is developing a new in-house concurrent engineering tool to facilitate concurrent engineering sessions. The team leveraged the many lessons learned and insight gained from using the current concurrent engineering tool, in use since 2007. SMEs have been involved throughout its design and development, ensuring accuracy and providing validity to the implementation approach. This new tool is database-driven and allows a team to work concurrently on the same model of a mission concept. “Workspaces” are provided for each of the traditional spacecraft mission design disciplines, including cost accounting and systems engineering. There are multiple tiers of fidelity available within each workspace, which can be completed parametrically or independently from the other disciplines as needed or synchronously with the other disciplines. A “commit” step synchronizes a workspace with the mission database and identifies any potential conflicts, along with the user who entered the conflicting data. A Mission Summary workspace enables a Study Lead to run an effective CE session, displaying key graphics, workspace status information, and technical and monetary budget information. This new CE tool will be undergoing Beta Testing with its primary user base and a limited Parts database in the summer of 2020. The team plans to release the first fully operational version in December 2020. Training: working in early concept development and maturation for a space mission requires a unique mindset and being comfortable with uncertainties in an environment where requirements are not yet fully developed, and where changes and trade-offs happen at a high tempo. The MDC started a weekly training program to ensure a common knowledge base on how do develop and mature early concept studies, as well as how to operate in a concurrent engineering environment. In conclusion, the MDC transformation will provide the overall PI community focused on cost-effective small satellite scientific missions with a powerful tool to address and mature early concepts more effectively and efficiently.

David Mauro↗
NASA NTRSDate not supplied

Low-Thrust Transfer to Interplanetary Trajectories from Lunar Trajectories with Rideshare

Accessing interplanetary space is challenging when using low thrust systems. Injecting spacecraft onto interplanetary trajectories is difficult with small launch vehicles, but it is possible to instead transfer to an interplanetary trajectory from a lunar flyby. Such cases are useful, for example, in rideshares between lunar and interplanetary missions. This work examines the problem of rideshare for small satellites onto lunar flyby trajectories, with transfers to an interplanetary trajectory. Low thrust interplanetary trajectories are examined starting from a rideshare mission on a lunar trajectory using delivery systems based on a modified Rocket Lab USA Electron vehicle and Photon stage.

Darcey R Graham↗
NASA NTRS2020

Deployable Entry Vehicles for Future Science and Exploration Missions

Deployable Entry Vehicle (DEV) technology has made significant advances over the last decade with ground test development campaigns and flight test demonstrations. DEVs offer benefits over traditional rigid entry vehicles including lower volume and mass, while enabling larger payload delivery and greater landing access. A crucial mission benefit is the DEV capability to transform from a compactly stowed configuration within the launch vehicle to a high drag area entry system for delivery of landers, rovers, aerial platforms, and orbiters (via aerocapture). These benefits span the range of mission classes from Small Satellite (smallsat) to human-class exploration systems. This paper will describe DEV technology development status, highlight mission concepts, and recommend future investments.

Alan Cassell↗
NASA NTRS2020

International Coordination and Support for SmallSat-enabled Space Weather Activities

Advances in space weather science and small satellite (SmallSat) technology have proceeded in parallel over the past two decades, but better communication and coordination is needed among the respective worldwide communities contributing to this rapid progress. We identify six areas where improved international coordination is especially desirable, including: (1) orbital debris mitigation; (2) spectrum management; (3) export control regulations; (4) access to timely and low-cost launch opportunities; (5) inclusive data policies; and (6) education. We argue the need for internationally coordinated policies and programs to promote the use of SmallSats for space weather research and forecasting while realizing maximum scientific and technical advances through the integration of these two increasingly important endeavors.

Teresa Nieves-Chinchilla↗
NASA NTRSDate not supplied

The Adaptable, Deployable, Entry and Placement Technology (ADEPT) Enabling Advanced Entry, Descent, and Landing Capabilities for SmallSat Missions

The Adaptable, Deployable Entry and Placement Technology (ADEPT) is a mechanically deployable low-ballistic coefficient aeroshell entry system which performs entry, descent, and landing (EDL) functions for a broad range of planetary destinations including Mars, Venus, Titan and Earth. The deployable system allows mission planners to develop an aeroshell design that is stowed like a folded umbrella, and yet prior to the EDL mission segment, transforms into a deployed, near-rigid low ballistic coefficient configuration. The ADEPT architecture is scalable from a sub-1m class to 6m diameter entry vehicles for Venus and and it has been studied at up to 15m – 20m scale for human exploration class missions. There has been growing interest in performing interplanetary missions with small spacecraft as secondary payloads and ADEPT offers small satellite mission designers the ability to consider Aeroassist technologies to expand mission applications. The ADEPT architecture introduces a new approach for entry vehicle design. It deploys a flexible 3D woven carbon fabric as the primary drag surface. It is capable of surviving high aerothermal heating during entry, while maintaining a robust impermeable membrane that provides high drag for vehicle deceleration. The ADEPT project team has advanced this decelerator technology via systems-level testing at the one meter diameter (nano-ADEPT) scale. A subsonic aeroloads test (May 2015) and a pathfinder arc-jet aeroheating test (Sept 2015) and a successful sounding rocket flight (SR-1) launch of a 0.7 meter deployed diameter ADEPT (September 2018). The SR-1 flight experiment demonstrated most of the primary end-to-end mission stages including: launch in a stowed configuration, separation and deployment in zero-g, exo-atmospheric conditions, and passive ballistic re-entry of a 70 degree half-angle cone geometry. The ADEPT SR-1 sounding rocket flight experiment had to address challenges such as stowing within the constrained payload envelope, fabric folding, and packaging concerns.

Paul Wercinski↗
NASA NTRSDate not supplied

Rollable Corrugated Tubular Booms

A promising candidate for a new class of deployable composite boom is the COrrugated ROllable TUbular Boom (COROTUB), which is to be employed on future large space structures by the National Aeronautics and Space Administration (NASA). The COROTUB’s two corrugated thin shells form a closed section, which yields high bending and torsional stiffness, allowing for high dimensional stability. The corrugation geometry that dictates the boom cross-section shape was completely defined by closed-form analytical equations given a set of key design parameters. Parametric studies of two geometric variables were used to evaluate which parameters most influence the cross-section’s area moment of inertia and torsional constant. The number of corrugations, flattened height of the boom, and concave and convex corrugation radii were varied to study the complete boom design space. Deeper corrugations increased the local buckling (crimpling) loads of the thin-shell boom but reduced the area moment of inertia and therefore the global buckling load of the beam-column member, and thus a fine balance was sought. Finite element analyses of pure bending and compression load cases for short, 1.22-m-long fully-deployed booms ofeither the same size (flattened height) or similar inertia properties, were first carried out to efficiently study this design trade-off in detail.A second computational study evaluated the boom transition shape and the structural response of a 6-m-long partially-deployed boom, where the effects of partially bracing the root of the boom were also assessed. It was found that bracing length could greatly affect the strength and stiffness of this boom.Bracing type (as in the discrete number of clamps at the root) had no effect on stiffness, but particularly impacted strength for loading cases and boundary conditions that promoted the onset of local web buckling at the root. The corrugated designs were also found to improve, by as much as 20%, the boom bending and axial strength and boom transition length from flat to deployed when compared to a state-of-the-art boom alternative of the same size, for short bracing distances, such as those that would be required by small satellite applications. In addition, they showed a comparable structural response for longer bracing supports.

Booms↗
NASA NTRSDate not supplied

Rocket Propulsion Test Design and Analysis

As the small satellite launch vehicle (SSLV) market grows and NASA continues to prepare for upcoming missions in the Artemis program, John C. Stennis Space Center’s (SSC) testing facilities must adapt to the increasing demand in liquid rocket engine testing. The Rocket Propulsion Test Design and Analysis Project for this rotation focused in both of this areas through two separate subprojects, the creation of a Private Rocket Engine Database and the automatization of the A1-Set Point Prediction Model. To identify the testing requirements of future Stennis Space Center (SSC) costumers, an excel spread sheet was commissioned as a database to collect technical and non-technical features of over one hundred privately developed liquid and hybrid rocket engine. Similarly, The A-1 Set Point Sheet Model is used to satisfy Aerojet Rocketdyne’s testing requirements of Net Positive Suction Pressure (NPSP) for the RS-25 staged combustion cycle engine. To expand the capabilities of this prediction model, a feed back loop was programmed to automate the search of setpoints using Excel Visual Basic for Applications (VBA).

John Paul Ortiz↗
NASA NTRS2019

Distributed Swarm Antenna Arrays for Deep Space Applications

It is desirable to develop a high Equivalent Isotropically Radiated Power (EIRP), autonomous, distributed, reconfigurable, on-demand Ka/X-band transmit-antenna array using small satellites, for deepspace communication (Mars and beyond). Our work shows that a distributed, free-flying swarm array composed of N CubeSats can not only be phased to provide a coherent beam in Ka/X-band, with performance (mass, power, data rate) comparable to the state-of-the-art Mars Reconnaissance Orbiter (MRO), but with N large, higher performance and data rates can be achieved, assuming a proper intra-swarm metrology system is in place.

Bevilacqua, Stefano↗
NASA NTRS2016

High Density Packaging Technologies for RF Electronics in Small Spacecraft

This paper will describe a few high density packaging technologies which we are currently exploring for use in current and future small spacecraft applications. The three categories of technologies include organic multichip modules (MCMs), ceramic leadless surface mount technology (SMT) and 3D printed waveguide structures. There are many other packaging technologies that currently exist but these three were selected in part due to their long heritage in various commercial, military and space applications along with each having a relatively clear path to flight. For each of these technologies, detailed examples will be included in which hardware has been fabricated and tested for use in RF electronics for spacecraft transponders. The organic MCM example will be described in most detail and it utilizes a packaging technology by the name of CoreEZ which is a trademark of i3 Electronics. This MCM has shrunk a portion of our electronics down to 1/8th of its previous area. The CoreEZ technology has been shown to be rad hard beyond a total ionizing dose (TID) of 300kRad and the MCM which was fabricated has gone through thermal cycling and shown to have no degradation in performance. The ceramic leadless package examples include packages from high reliability manufactures by the name of KCB solutions and Barry Industries. In the case of KCB solutions, we have multiple products that will be described including a hermetic ceramic carrier which houses three microwave monolithic integrated circuits (MMICs) along with small discrete components. Finally, we will discuss the results of our search for a 3D printing process that allows us to reduce the cost and volume of our waveguide filters and diplexers for low cost small satellite applications. We have fabricated a few prototypes using direct metal laser sintering (DMLS) and metal coated plastics. Each of these packaging technology discussions will have a brief overview of its current and future use.

Schatzel, Donald↗
NASA NTRS2017

HydroCube Mission Concept: P-Band Signals of Opportunity for Remote Sensing of Snow and Root Zone Soil Moisture

We have developed the HydroCube mission concept with a constellation of small satellites to remotely sense Snow Water Equivalent (SWE) and Root Zone Soil Moisture (RZSM). The HydroCube satellites would operate at sun-synchronous 3-day repeat polar orbits with a spatial resolution of about 1-3 Km. The mission goals would be to improve the estimation of terrestrial water storage and weather forecasts. Root-zone soil moisture and snow water storage in land are critical parameters of the water cycle. The HydroCube Signals of Opportunity (SoOp) concept utilizes passive receivers to detect the reflection of strong existing P-band radio signals from geostationary Mobile Use Objective System (MUOS) communication satellites. The SWE remote sensing measurement principle using the P-band SoOp is based on the propagation delay (or phase change) of radio signals through the snowpack. The time delay of the reflected signal due to the snowpack with respect to snow-free conditions is directly proportional to the snowpack SWE. To address the ionospheric delay at P-band frequencies, the signals from both MUOS bands (360-380 MHz and 250-270 MHz) would be used. We have conducted an analysis to trade off the spatial resolution for a space-based sensor and measurement accuracy. Through modeling analysis, we find that the dual-band MUOS signals would allow estimation of soil moisture and surface roughness together. From the two MUOS frequencies at 260 MHz and 370 MHz, we can retrieve the soil moisture from the reflectivity ratio scaled by wavenumbers using the two P-band frequencies for MUOS. A modeling analysis using layered stratified model has been completed to determine the sensitivity requirements of HydroCube measurements. For mission concept demonstration, a field campaign has been conducted at the Fraser Experimental Forest in Colorado since February 2016. The data acquired has provided support to the HydroCube concept.

Derksen, Chris↗
NASA NTRS2018

SpaceWire as a Cube-Sat Instrument Interface

SpaceWire is used in the control and data interface for an instrument on a pair of small satellites, one of which was launched in summer 2017. The instrument SpaceWire interface is implemented in a Field Programmable Gate Array as an instantiated core controlled by a LEON3FT CPU, which is also implemented as an instantiated core. The UT699 processor in the flight computer provides the spacecraft side’s SpaceWire interface. A simple message based protocol consisting of four message types was defined, based on existing SpaceWire standards. One was for passing commands to and responses from the instrument in the form of text strings similar to those from a system console where each line of text is passed in a SpaceWire message. Another was for passing spacecraft time to the instrument. The third was for transferring files using a subset of the Remote Memory Access Protocol (RMAP). The fourth was for retrieving science data from the instrument. A set of user application programming interface (API) routines provided an abstracted interface to both the serial console (used during debug) and the SpaceWire device interface. Early instrument development and testing was done with a set of utilities that controlled a Star-Dundee USB-SpaceWire brick providing a user interface similar to a serial console terminal emulator with the addition of file and data transfers. Later in the integration and test process, these utilities were integrated with the COSMOS ground systems software used for spacecraft control, providing a seamless transition from standalone instrument tests to benchtop flat-sat test and full spacecraft level tests.

Lux, James P.↗
NASA NTRS2018

Ground System Development at the Morehead State University for Interplanetary Smallsat Missions

As more small satellites are used for interplanetary research and exploration, more ground antennas with sufficiently large aperture are needed to support the increased demand in deep space communication. The 21-m ground antenna at the Morehead State University in Kentucky, United States is under development to upgrade its telemetry, tracking and command capability at X-band. The system architecture is based on a hybrid design that combines commercially available products with specialized equipment developed for the National Aeronautic and Aerospace Administration’s Deep Space Network. This architecture produces a low-cost and geographically diverse system, connecting elements at the Morehead State University and those of the DSN at the Jet Propulsion Laboratory in Pasadena, California. The architecture makes Morehead antenna appears as one of the DSN nodes, albeit with a different performance metrics due to difference in aperture size. Its operation is geared for automation, with automated data retrieval of information needed for configuring the ground station for spacecraft tracking. An incremental testing approach is used to verify system capabilities as various components are deployed into the system.

Kruth, Jeff↗