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Cost-Effective Additive Manufacturing in Space: HELIOS Technology Challenge Guide

Welcome to the HELIOS Technology Challenge Guide. This document is intended to serve as a general road map for participants of the HELIOS Technology Challenge [HTC] Program and the associated inaugural challenge: HTC-01: Cost-Effective Additive Manufacturing in Space. Please note that this guide is not a rule book and is not meant to hinder the development of innovative ideas. Its primary goal is to highlight the objectives of the HTC-01 Challenge and to describe possible solution routes and pitfalls that such technology may encounter in space. Please also note that participants wishing to demonstrate any hardware developed under this program during any future HELIOS Technology Challenge showcase event(s) may be subject to event regulations to be published separately at a later date.

DeVieneni, Alayna↗

The 13th Technology of Deep Space One

On October 24th, 1998, the Deep Space One (DS-1) spacecraft launched aboard a Delta II rocket as the first step towards the bold task of testing and validating 12 new technologies for future missions. This launch also represented yet another thrilling event; namely, the successful test and validation of a 13th heretofore undisclosed technology: model-base-code-generation of the spacecraft's system-level fault-protection (FP) software from behavioral state diagrams and structural models.

model-based-code-generation↗

NASA Astrophysics Division Technology Heritage Study

The National Aeronautics and Space Administration’s (NASA) Astrophysics Division (APD) funds and manages missions and studies that seek to broaden our understanding of our place in the universe. These science missions are enabled by technologies developed through APD’s technology development programs. APD has funded approximately seven different technology development programs over the last ten years which support basic research and target varying Technology Readiness Levels (TRLs). The funding has targeted technology for future space flight experiments as well as suborbital science investigations. To understand the overall impact of APD’s investment on astrophysics technology advancement through their grants and contracts, APD engaged The Aerospace Corporation to conduct an independent, comprehensive Astrophysics Technology Heritage Study. The study was conducted in the 2021-2022 timeframe, first focusing priority on infusion of competed grants and general trends, followed by directed grants and further trend analysis and technology characterization. The study included three major components: a grants database, a missions database, and a survey of Principal Investigators (PIs). The study found that APD grants and contracts fund a healthy portfolio of technologies that resulted in an overall 62% infusion rate, as suborbital missions provide ample science and technology maturation and platform transition opportunities. Within the 62% of infused grants, 12% were infused into space missions and another 31% were suborbital. The study also looked at various other characteristics of the grant awards including the organizations they were awarded to and award trends by PI. Technology focus areas and detector types were also investigated, as well as technology platform transitions from on mission environment (e.g., suborbital to space). Additional feedback from PIs was also requested and evaluated including alternative benefits of grants and reasons development did, or did not, succeed.

NASA↗

Next Generation Life Support Project Status

Next Generation Life Support (NGLS) is one of over twenty technology development projects sponsored by NASA's Game Changing Development Program. The NGLS Project develops selected life support technologies needed for humans to live and work productively in space, with focus on technologies for future use in spacecraft cabin and space suit applications. Over the last three years, NGLS had five main project elements: Variable Oxygen Regulator (VOR), Rapid Cycle Amine (RCA) swing bed, High Performance (HP) Extravehicular Activity (EVA) Glove, Alternative Water Processor (AWP) and Series-Bosch Carbon Dioxide Reduction. The RCA swing bed, VOR and HP EVA Glove tasks are directed at key technology needs for the Portable Life Support System (PLSS) and pressure garment for an Advanced Extravehicular Mobility Unit (EMU). Focus is on prototyping and integrated testing in cooperation with the Advanced Exploration Systems (AES) Advanced EVA Project. The HP EVA Glove Element, new this fiscal year, includes the generation of requirements and standards to guide development and evaluation of new glove designs. The AWP and Bosch efforts focus on regenerative technologies to further close spacecraft cabin atmosphere revitalization and water recovery loops and to meet technology maturation milestones defined in NASA's Space Technology Roadmaps. These activities are aimed at increasing affordability, reliability, and vehicle self-sufficiency while decreasing mass and mission cost, supporting a capability-driven architecture for extending human presence beyond low-Earth orbit, along a human path toward Mars. This paper provides a status of current technology development activities with a brief overview of future plans.

Barta, Daniel J.↗

Ka-band MMIC array feed development for deep space applications

Ka-band MMIC transmitter arrays are under development at NASA Jet Propulsion Laboratory for future deep space and ground communication needs. A high efficiency full aperture active antenna array is desired to demonstrate solid state array technology for future NASA missions. This paper reports on a 5 watt Ka-band phased array feed and a full aperture active array for a mobile terminal which are being developed to characterize the design tradeoffs and potential of solid state Ka-band MMIC array communication systems.

Cooley, T. W.↗

Materials and devices for fundamental quantum science and quantum technologies

Technologies operating on the basis of quantum mechanical laws and resources such as phase coherence and entanglement are expected to revolutionize our future. Quantum technologies are often divided into four main pillars: computing, simulation, communication, and sensing & metrology. Moreover, a great deal of interest is currently also nucleating around energy-related quantum technologies. In this Perspective, we focus on advanced superconducting materials, van der Waals materials, and moiré quantum matter, summarizing recent exciting developments and highlighting a wealth of potential applications, ranging from high-energy experimental and theoretical physics to quantum materials science and energy storage.

Polini, Marco↗

Scaling and statistics of bottom-up synthesized armchair graphene nanoribbon transistors

Bottom-up assembled nanomaterials and nanostructures allow for the studies of rich and unprecedented quantum-related and mesoscopic transport phenomena. However, it can be difficult to quantify the correlations between the geometrical or structural parameters obtained from advanced microscopy and measured electrical characteristics when they are made into macroscopic devices. Here, we propose a strategy to connect the nanomaterial morphologies and the device performance through a Monte Carlo device model and apply it to understand the scaling trends of bottom-up synthesized armchair graphene nanoribbon (GNR) transistors. A new nanofabrication process is developed for GNR transistors with channel length down to 7 nm. Further, the impacts of the GNR spatial distributions and the device geometries on the device performance are investigated systematically through comparison of experimental data with the model. Through this study, challenges and opportunities of transistor technologies based on bottom-up synthesized GNRs are pinpointed, paving the way to the further improvement of the GNR device performance for future transistor technology nodes.

36 MATERIALS SCIENCE↗

Application of narrow-band television to industrial and commercial communications

The development of narrow-band systems for use in space systems is presented. Applications of the technology to future spacecraft requirements are discussed along with narrow-band television's influence in stimulating development within the industry. The transferral of the technology into industrial and commercial communications is described. Major areas included are: (1) medicine; (2) education; (3) remote sensing for traffic control; and (5) weather observation. Applications in data processing, image enhancement, and information retrieval are provided by the combination of the TV camera and the computer.

Embrey, B. C., Jr.↗

Systems engineering overview for regenerative life-support systems applicable to space habitats

The Life-Support Systems Group of the 1977 NASA Ames Summer Study conducted analyses initially to identify areas where partial or complete closure of the life-support system, for various types of space habitats, should be considered, and to develop a sound methodology for identifying, screening, and evaluating alternative closure schemes. Results of these analyses, including the systems engineering considerations that affect technology-development planning and management for regenerative life-support systems, are discussed. A recommended methodology is also presented as a basis for future technology-development activities in this area.

Spurlock, J.↗

Deep Space Systems Technology Program (DSST-X2000) Future Deliveries

The number of deep space missions is increasing as we embark on a new era of exploration. New missions are "faster-better-cheaper" and cannot afford large individual investments in technology. A new process is needed fo allow these missions to take advantage of the technological breakthroughs that are critical to getting the cost down while increasing the science. The key is multimission technology development. NASA will make institutional investments in technology to benefit sets of missions. Continuous investment will provide a series of revolutions in technology to address common challenges in mission design and execution.

Salvo, Christopher G.↗

Considerations For Waste-to-Base Future Research Paths

Developing innovative technologies to reprocess low value waste into high value base products will enable a new “Waste-to-Base” (WtB) capability that can spawn a new approach to mission design. Systems engineers and mission architects will work together under a new paradigm in logistics planning. Equipment, components, packaging, storage, and structures will be understood not only by functional requirements, but also in terms of useful lifetimes and materials of construction. The advent of a new technical discipline - reprocess engineering - will grow from the intersection between chemical, mechanical, and systems engineering, mission design, and logistics planning. A crowdsourcing approach was employed to gather low TRL concepts into workable solutions for issues in trash management, CO2 processing, foam re-processing, and fecal processing. The results of the crowdsourcing activities are summarized along with a roadmap for future technology development work.

Logistics reduction↗

Plasma-based particle sources

High-brightness particle beams generated by advanced accelerator concepts have the potential to become an essential part of future accelerator technology. In particular, high-gradient accelerators can generate and rapidly accelerate particle beams to relativistic energies. The rapid acceleration and strong confining fields can minimize irreversible detrimental effects to the beam brightness that occur at low beam energies, such as emittance growth or pulse elongation caused by space charge forces. Due to the high accelerating gradients, these novel accelerators are also significantly more compact than conventional technology. Advanced accelerators can be extremely variable and are capable of generating particle beams with vastly different properties using the same driver and setup with only modest changes to the interaction parameters. So far, efforts have mainly been focused on the generation of electron beams, but there are concepts to extend the sources to generate spin-polarized electron beams or positron beams. The beam parameters of these particle sources are largely determined by the injection and subsequent acceleration processes. Although, over the last decade there has been significant progress, the sources are still lacking a sufficiently high 6-dimensional (D) phase-space density that includes small transverse emittance, small energy spread and high charge, and operation at high repetition rate. This is required for future particle colliders with a sufficiently high luminosity or for more near-term applications, such as enabling the operation of free-electron lasers (FELs) in the X-ray regime. Major research and development efforts are required to address these limitations in order to realize these approaches for a front-end injector for a future collider or next-generation light sources. In particular, this includes methods to control and manipulate the phase-space and spin degrees-of-freedom of ultrashort plasma-based electron bunches with high accuracy, and methods that increase efficiency and repetition rate. These efforts also include the development of high-resolution diagnostics, such as full 6D phase-space measurements, beam polarimetry and high-fidelity simulation tools. A further increase in beam luminosity can be achieve through emittance damping. Emittance cooling via the emission of synchrotron radiation using current technology requires kilometer-scale damping rings. For future colliders, the damping rings might be replaced by a substantially more compact plasma-based approach. Here, plasma wigglers with significantly stronger magnetic fields are used instead of permanent-magnet based wigglers to achieve similar damping performance but over a two orders of magnitude reduced length.

43 PARTICLE ACCELERATORS↗

STREAM: A technology planning and capacity expansion model for the industrial sector

The Strategic Technology Roadmapping and Energy, Environmental, and Economic Analysis Model—STREAM—is an optimization-based modeling tool and analysis framework to assist with strategic planning and technology investments of the industrial sector. This open-source framework is written in Julia using the JuMP package, which enables users to model future “pathways” for incumbent and future production technologies, costs, fuels and energy carriers, and energy and non-energy environmental impacts from industries as they transform in pursuit of a robust and competitive manufacturing sector. The model starts with an initial stock of industrial production technologies and assets at a facility level and then determines pathways that minimize cost, subject to an array of possible constraints on demand, market shares, environmental flows, and other exogenously specified operational considerations such as capacity utilization rates or regional energy costs. Key features of the framework include flexibility to model a wide range of industries and industrial technologies/processes at varying levels of granularity, ability to perform parametric sensitivity analyses, and ability to visualize model results using visualization objects.

capacity expansion↗

Energy Efficient Engine: Flight propulsion system final design and analysis

The Energy Efficient Engine (E3) is a NASA program to create fuel saving technology for future transport engines. The Flight Propulsion System (FPS) is the engine designed to achieve E3 goals. Achieving these goals required aerodynamic, mechanical and system technologies advanced beyond that of current production engines. These technologies were successfully demonstrated in component rigs, a core engine and a turbofan ground test engine. The design and benefits of the FPS are presented. All goals for efficiency, environmental considerations, and economic payoff were met. The FPS has, at maximum cruise, 10.67 km (35,000 ft), M0.8, standard day, a 16.9 percent lower installed specific fuel consumption than a CF6-50C. It provides an 8.6 percent reduction in direct operating cost for a short haul domestic transport and a 16.2 percent reduction for an international long distance transport.

Davis, Donald Y.↗

Status of the Advanced Reusable Technologies Project

The Advanced Reusable Technologies (ART) Project, part of the Advanced Space Transportation Program Office at the NASA's Marshall Space Flight Center in Huntsville, Ala., focuses on future reusable technologies beyond those being pursued by X-33. The prime objective of the project is to dramatically reduce the cost of access to space. In April 1996, an NRA was issued soliciting proposals for tasks focusing on rocket-based combined cycle propulsion system (RBCC). In August of 1996, five contractors were selected for a two year period to design and ground test their RBCC engine concepts. The work on these contracts should be completed by the end of this year. In March of this year, another NRA was issued to solicit inputs for reusable vehicle and propulsion technologies applicable to earth-to-orbit and in-space transportation. The current RBCC effort is the first of three phases leading to a large scale flight demonstrations of the technology for space launch vehicle propulsion. This first phase will provide initial verification of proposed concepts through ground demonstration of combined rocket/air breathing propulsion technologies. Using the most promising concepts identified in the first phase, the second phase will design, manufacture and ground test flight-type engine(s) to demonstrate actual design weights and performance. In the third phase, the first flight of a sub-scale integrated X-vehicle is planned for 2002. This paper describes the current status, plans and progress of the ART Project.

Hueter, Ume↗

Advanced Controller Developed for the Free-Piston Stirling Convertor

A free-piston Stirling power convertor is being considered as an advanced power-conversion technology for future NASA deep-space missions requiring long-life radioisotope power systems. The NASA Glenn Research Center has identified key areas where advanced technologies can enhance the capability of Stirling energy-conversion systems. One of these is power electronic controls. Current power-conversion technology for Glenn-tested Stirling systems consists of an engine-driven linear alternator generating an alternating-current voltage controlled by a tuning-capacitor-based alternating-current peak voltage load controller. The tuning capacitor keeps the internal alternator electromotive force (EMF) in phase with its respective current (i.e., passive power factor correction). The alternator EMF is related to the piston velocity, which must be kept in phase with the alternator current in order to achieve stable operation. This tuning capacitor, which adds volume and mass to the overall Stirling convertor, can be eliminated if the controller can actively drive the magnitude and phase of the alternator current.

Gerber, Scott S.↗

Satellite Communications for Aeronautics Applications: Technology Development and Demonstration

The National Aeronautics and Space Administration (NASA) is performing research and development to improve the safety and increase the capacity of the National Airspace System (NAS). Improved communications, especially to and from the aircraft flight deck, has been identified as an essential enabling technology for future improvements to the air traffic management system and aviation safety. NASA's Glenn Research Center is engaged in research and development of satellite communications technologies for aeronautical applications. A mobile aero terminal has been developed for use with Ku band commercial communications satellites. This experimental terminal will be used in mobile ground and air-based tests and demonstrations during 2000-2004. This paper will describe the basic operational parameters of the Ku Band aero terminal, the communications architecture it is intended to demonstrate, and the key technology issues being addressed in the tests and demonstrations. The design of the Ku Band aero terminal and associated ground testbed, planned tests and demonstrations, and results to date will be presented.

Kerczewski, Robert J.↗