Integrated Multiscale Model for Design of Robust 3D Solid-state Lithium Batteries
Abstract not provided.
25 ENERGY STORAGE↗
SEARCH · Engineering Papers
Results for “3D integration”
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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3D Metrology for Process Control and Structure Integrity for Evaluating MEMS Reliability for Space Applications
MEMS fabrication processes are as diverse as their applications.
MEMS Process↗
Novel technology of non-contact real-time radiation damage sensors for high power targets.
This report summarizes the contributions of an intern participating in the Community College Internship (CCI) program at Fermilab, focusing on the development of a novel, non-contact, real-time radiation damage sensor technology. The core objective is to create a reliable sensor capable of measuring radiation-induced degradation on high-power targets without physical contact. The experiment involves using a Class 3B supercontinuum laser directed toward a single material sample placed within a vacuum test chamber. The laser beam reflects off the sample's surface, with changes in reflectivity, indicative of radiation damage, measured by a spectrometer positioned at the chamber’s output port. The intern’s primary responsibilities included designing an interlock system to ensure laser operational safety, developing a camera-based monitoring system using Raspberry Pi devices, and creating structural supports using 3D modeling and printing techniques. Components for the interlock and camera systems were successfully designed and ordered, with preliminary 3D models printed and refined through iterative testing. Challenges encountered in the 3D printing process, such as fragile initial prototypes and difficult support removal, were overcome by adjusting printer settings and incorporating design enhancements like chamfered edges. Future activities, pending component delivery, involve installing and configuring the interlock and camera systems, as well as further improving the structural supports. Overall, the internship significantly enhanced the intern’s technical proficiency in hardware design, software integration, and advanced 3D printing, contributing directly to Fermilab’s operational safety standards and experimental effectiveness in high-energy physics research.
Pumarino Meza, Rafael [Unlisted; Fermilab]↗
Autonomous elemental characterization enabled by a low cost robotic platform built upon a generalized software architecture
Despite the rapidly growing applications of robots in industry, the use of robots to automate tasks in scientific laboratories is less prolific due to the lack of generalized methodologies and the high cost of hardware. This paper focuses on the automation of characterization tasks necessary for reducing cost while maintaining generalization and proposes a software architecture for building robotic systems in scientific laboratory environments. A dual-layer (Socket.IO and ROS) action server design is the basic building block, which facilitates the implementation of a web-based front end for user-friendly operation and the use of ROS Behavior Trees for convenient task planning and execution. A robotic platform for automating mineral and material sample characterization is built upon the architecture, with an open-source, low-cost three-axis computer numerical control gantry system serving as the main robot. A handheld laser induced breakdown spectroscopy (LIBS) analyzer is integrated with a 3D printed adapter, enabling (1) automated 2D chemical mapping and (2) autonomous sample measurement (with the support of an RGB-Depth camera). We demonstrate the utility of automated chemical mapping by scanning the surface of a spodumene-bearing pegmatite core sample with a 1071-point dense hyperspectral map acquired at a rate of 1520 bits per second. Furthermore, we showcase the autonomy of the platform in terms of perception, dynamic decision-making, and execution, through a case study of LIBS measurement of multiple mineral samples. The platform enables controlled and autonomous chemical quantification in the laboratory that complements field-based measurements acquired with the same handheld device, linking resource exploration and processing steps in the supply chain for lithium-based battery materials.
Cao, Xuan [Lawrence Berkeley National Laboratory (↗
Modeling Leadership Styles in Human-Robot Team Dynamics
The recent proliferation of robotic systems in our society has placed questions regarding interaction between humans and intelligent machines at the forefront of robotics research. In response, our research attempts to understand the context in which particular types of interaction optimize efficiency in tasks undertaken by human-robot teams. It is our conjecture that applying previous research results regarding leadership paradigms in human organizations will lead us to a greater understanding of the human-robot interaction space. In doing so, we adapt four leadership styles prevalent in human organizations to human-robot teams. By noting which leadership style is more appropriately suited to what situation, as given by previous research, a mapping is created between the adapted leadership styles and human-robot interaction scenarios-a mapping which will presumably maximize efficiency in task completion for a human-robot team. In this research we test this mapping with two adapted leadership styles: directive and transactional. For testing, we have taken a virtual 3D interface and integrated it with a genetic algorithm for use in &le-operation of a physical robot. By developing team efficiency metrics, we can determine whether this mapping indeed prescribes interaction styles that will maximize efficiency in the teleoperation of a robot.
Cruz, Gerardo E.↗
Modeling the Effects of Beam Size and Flaw Morphology on Ultrasonic Pulse/Echo Sizing of Delaminations in Carbon Composites
The size and shape of a delamination in a multi-layered structure can be estimated in various ways from an ultrasonic pulse/echo image. For example the -6dB contours of measured response provide one simple estimate of the boundary. More sophisticated approaches can be imagined where one adjusts the proposed boundary to bring measured and predicted UT images into optimal agreement. Such approaches require suitable models of the inspection process. In this paper we explore issues pertaining to model-based size estimation for delaminations in carbon fiber reinforced laminates. In particular we consider the influence on sizing when the delamination is non-planar or partially transmitting in certain regions. Two models for predicting broadband sonic time-domain responses are considered: (1) a fast "simple" model using paraxial beam expansions and Kirchhoff and phase-screen approximations; and (2) the more exact (but computationally intensive) 3D elastodynamic finite integration technique (EFIT). Model-to-model and model-to experiment comparisons are made for delaminations in uniaxial composite plates, and the simple model is then used to critique the -6dB rule for delamination sizing.
Margetan, Frank J.↗
Simulation Based Investigation of Hidden Delamination Damage Detection in CFRP Composites
Guided wave (GW) based damage detection methods have shown promise in structural health monitoring (SHM) and hybrid SHM-nondestructive evaluation (NDE) techniques. Much previous GW work in the aerospace field has been primarily focused on metallic materials, with a growing focus on composite materials. The work presented in this paper demonstrates how realistic three-dimensional (3D) GW simulations can aid in the development of GW based damage characterization techniques for aerospace composites. 3D elastodynamic finite integration technique is implemented to model GW interaction with realistic delamination damage. A local wavenumber technique is applied to simulation data in order to investigate the detectability of hidden delamination damage to enable accurate characterization of damage extent.
Leckey, Cara A. C.↗
AAM NC ATI TechTalk - Aerograph Architecture v1
Aerograph is NASA’s data management system for Advanced Air Mobility. Its mission is to support AAM research by providing a reliable and secure system that collects, stores, protects, and shares AAM data. Its vision is to provide a system that AAM research scientists, aerospace engineers, data scientists, and analysts trust for obtaining NC data and performing key analyses. The types of data Aerograph manages involves data related to flight test events, including: Aircraft Performance and Characterization (e.g., position reports) Airspace (e.g., operation intent, waypoints, and constraints) Environment (e.g., surface and wind weather) Infrastructure (e.g., surveillance coverage) Derivative Analytical Artifacts (e.g., glide path performance chart, 3D position chart, Integrated Data Product)
Aerograph↗
Pushing the Limits of Cubesat Attitude Control: A Ground Demonstration
A cubesat attitude control system (ACS) was designed at the NASA Marshall Space Flight Center (MSFC) to provide sub-degree pointing capabilities using low cost, COTS attitude sensors, COTS miniature reaction wheels, and a developmental micro-propulsion system. The ACS sensors and actuators were integrated onto a 3D-printed plastic 3U cubesat breadboard (10 cm x 10 cm x 30 cm) with a custom designed instrument board and typical cubesat COTS hardware for the electrical, power, and data handling and processing systems. In addition to the cubesat development, a low-cost air bearing was designed and 3D printed in order to float the cubesat in the test environment. Systems integration and verification were performed at the MSFC Small Projects Rapid Integration & Test Environment laboratory. Using a combination of both the miniature reaction wheels and the micro-propulsion system, the open and closed loop control capabilities of the ACS were tested in the Flight Robotics Laboratory. The testing demonstrated the desired sub-degree pointing capability of the ACS and also revealed the challenges of creating a relevant environment for development testin
Sanders, Devon S.↗
Recent Advances in Visualizing 3D Flow with LIC
Line Integral Convolution (LIC), introduced by Cabral and Leedom in 1993, is an elegant and versatile technique for representing directional information via patterns of correlation in a texture. Although most commonly used to depict 2D flow, or flow over a surface in 3D, LIC methods can equivalently be used to portray 3D flow through a volume. However, the popularity of LIC as a device for illustrating 3D flow has historically been limited both by the computational expense of generating and rendering such a 3D texture and by the difficulties inherent in clearly and effectively conveying the directional information embodied in the volumetric output textures that are produced. In an earlier paper, we briefly discussed some of the factors that may underlie the perceptual difficulties that we can encounter with dense 3D displays and outlined several strategies for more effectively visualizing 3D flow with volume LIC. In this article, we review in more detail techniques for selectively emphasizing critical regions of interest in a flow and for facilitating the accurate perception of the 3D depth and orientation of overlapping streamlines, and we demonstrate new methods for efficiently incorporating an indication of orientation into a flow representation and for conveying additional information about related scalar quantities such as temperature or vorticity over a flow via subtle, continuous line width and color variations.
Interrante, Victoria↗
Celestial Mapping System and Digital Lunar Library Initiative
We are preparing to create an interactive, global 3D lunar environment with integrated dataset and AI/ML tools to provide unique value to mission planners, scientists and the entire lunar community. This lunar environment will be based on NASA Ames Celestial Mapping System (CMS) [1] and Digital Lunar Library (DLL) Initiative. CMS provides a 3D virtual Lunar Globe with extensive user friendly tool sets, that include high resolution terrain visualization, elevation profiles, measurement kits, slope analysis, path optimization, line of sight analysis, equipment planning and placement tools and many other functionalities [1]. It has a thick client with less overhead to access hardware resources. This allows features such as terrain profiling and distance calculations to be performed on the client and on the fly. The application is developed to provide situational and domain awareness on the Lunar surface, planning capabilities for equipment placements and traverse path optimization. As data becomes available, CMS has the capabilities to integrate data sets that change dynamically in real-time, which will be useful for monitoring satellites and remotely-sensed data on the Lunar surface. CMS supports importing synthetic features in a variety of 3D, 2D, vector and raster formats. In the future, these capabilities will be enhanced by incorporating AI/ML tools and a plug-in architecture to enable customization by the user groups. With the help of DLL we will be able to : 1) Amplify the value of lunar information with AI-powered data enhancements 2) Acquire and integrate lunar data with AI-assisted georectification and homogenization 3) Analyze lunar data with advanced 3D visualization, intelligent search-by-example 4) Apply lunar data insights to specific use cases with an open plug-in architecture. The CMS-DLL initiative will have several potential use cases for NASA and the lunar community in general, including subsurface lava tube visualization and analysis, soil analysis, in-situ lunar resource visualization and representation on 3D globe, and data analytics for utilization. REFERENCES: [1] https://celestial.arc.nasa.gov/
3D Globe↗
3D Printing Multi-Functionality: Embedded RF Antennas and Components
Significant research and press has recently focused on the fabrication freedom of Additive Manufacturing (AM) to create both conceptual models and final end-use products. This flexibility allows design modifications to be immediately reflected in 3D printed structures, creating new paradigms within the manufacturing process. 3D printed products will inevitably be fabricated locally, with unit-level customization, optimized to unique mission requirements. However, for the technology to be universally adopted, the processes must be enhanced to incorporate additional technologies; such as electronics, actuation, and electromagnetics. Recently, a novel 3D printing platform, Multi3D manufacturing, was funded by the presidential initiative for revitalizing manufacturing in the USA using 3D printing (America Makes - also known as the National Additive Manufacturing Innovation Institute). The Multi3D system specifically targets 3D printed electronics in arbitrary form; and building upon the potential of this system, this paper describes RF antennas and components fabricated through the integration of material extrusion 3D printing with embedded wire, mesh, and RF elements.
antennas↗
Fabrication of Single, Vertically Aligned Carbon Nanotubes in 3D Nanoscale Architectures
Plasma-enhanced chemical vapor deposition (PECVD) and high-throughput manufacturing techniques for integrating single, aligned carbon nanotubes (CNTs) into novel 3D nanoscale architectures have been developed. First, the PECVD growth technique ensures excellent alignment of the tubes, since the tubes align in the direction of the electric field in the plasma as they are growing. Second, the tubes generated with this technique are all metallic, so their chirality is predetermined, which is important for electronic applications. Third, a wafer-scale manufacturing process was developed that is high-throughput and low-cost, and yet enables the integration of just single, aligned tubes with nanoscale 3D architectures with unprecedented placement accuracy and does not rely on e-beam lithography. Such techniques should lend themselves to the integration of PECVD grown tubes for applications ranging from interconnects, nanoelectromechanical systems (NEMS), sensors, bioprobes, or other 3D electronic devices. Chemically amplified polyhydroxystyrene-resin-based deep UV resists were used in conjunction with excimer laser-based (lambda = 248 nm) step-and-repeat lithography to form Ni catalyst dots = 300 nm in diameter that nucleated single, vertically aligned tubes with high yield using dc PECVD growth. This is the first time such chemically amplified resists have been used, resulting in the nucleation of single, vertically aligned tubes. In addition, novel 3D nanoscale architectures have been created using topdown techniques that integrate single, vertically aligned tubes. These were enabled by implementing techniques that use deep-UV chemically amplified resists for small-feature-size resolution; optical lithography units that allow unprecedented control over layer-to-layer registration; and ICP (inductively coupled plasma) etching techniques that result in near-vertical, high-aspect-ratio, 3D nanoscale architectures, in conjunction with the use of materials that are structurally and chemically compatible with the high-temperature synthesis of the PECVD-grown tubes. The techniques offer a wafer-scale process solution for integrating single PECVD-grown nanotubes into novel architectures that should accelerate their integration in 3D electronics in general. NASA can directly benefit from this technology for its extreme-environment planetary missions. Current Si transistors are inherently more susceptible to high radiation, and do not tolerate extremes in temperature. These novel 3D nanoscale architectures can form the basis for NEMS switches that are inherently less susceptible to radiation or to thermal extremes.
Kaul, Anupama B.↗
Increasing Efficiency of Underground Geologic Mapping by Integrating Mine Vision System FaceCapture™ Data Collection with Datamine 3D Modeling Software
Explore the source record for details and available documents.
58 GEOSCIENCES↗
Computational Simulation of Damage Propagation in Three-Dimensional Woven Composites
Three dimensional (3D) woven composites have demonstrated multi-directional properties and improved transverse strength, impact resistance, and shear characteristics. The objective of this research is to develop a new model for predicting the elastic constants, hygrothermal effects, thermomechanical response, and stress limits of 3D woven composites; and to develop a computational tool to facilitate the evaluation of 3D woven composite structures with regard to damage tolerance and durability. Fiber orientations of weave and braid patterns are defined with reference to composite structural coordinates. Orthotropic ply properties and stress limits computed via micromechanics are transformed to composite structural coordinates and integrated to obtain the 3D properties. The various stages of degradation, from damage initiation to collapse of structures, in the 3D woven structures are simulated for the first time. Three dimensional woven composite specimens with various woven patterns under different loading conditions, such as tension, compression, bending, and shear are simulated in the validation process of this research. Damage initiation, growth, accumulation, and propagation to fracture are included in these simulations.
Huang, Dade↗
High Precision, High Frequency Printed Antennas
An emerging trend in advanced manufacturing is printed electronics and sensors. The ability to print customized electronics and sensors integrated into functional packages is a growing need within a variety of growing markets such as smart manufacturing, internet of things (IoT), and the small satellite industry. Both Oak Ridge National Laboratory (ORNL) and the MITRE Corporation have seedling research efforts evaluating the potential for future printed electronic systems. High frequency, wide-bandwidth phased array antennas (i.e. >45 GHz) open the door to new applications. However, such sensors require currently prohibitively small feature sizes for commercial 3D printing technologies along with increasing challenges with connecting the driving electronics to such features. An additional finding with related advanced manufacturing challenges is the rapid production of 3D additive connectors for integration with commercial printed circuit boards (PCBs), primarily for advanced in-circuit inspection techniques. This work is developing additive manufacturing processes for producing connected and conductive fine scale 3D features. The primary focus was on aerosol-jet printing (AJP), which has a small minimum resolution (<50 µm) but is traditionally printed flat with small height/width aspect ratios <<1, and developing controls to enable fully 3D, high aspect ratio, and unsupported features. In Phase 1 of this effort, baselines of process performance were characterized, and test coupons produced for both ultra-high frequency antennas and microstructures to support reverse engineering of PCBs. In Phase 2, these efforts will be extended for system demonstration of ultra-high frequency antenna arrays, as well as reverse engineering circuitry for dense PCBs.
42 ENGINEERING↗
A Large-Scale Design Integration Approach Developed in Conjunction with the Ares Launch Vehicle Program
This paper presents a method for performing large-scale design integration, taking a classical 2D drawing envelope and interface approach and applying it to modern three dimensional computer aided design (3D CAD) systems. Today, the paradigm often used when performing design integration with 3D models involves a digital mockup of an overall vehicle, in the form of a massive, fully detailed, CAD assembly; therefore, adding unnecessary burden and overhead to design and product data management processes. While fully detailed data may yield a broad depth of design detail, pertinent integration features are often obscured under the excessive amounts of information, making them difficult to discern. In contrast, the envelope and interface method results in a reduction in both the amount and complexity of information necessary for design integration while yielding significant savings in time and effort when applied to today's complex design integration projects. This approach, combining classical and modern methods, proved advantageous during the complex design integration activities of the Ares I vehicle. Downstream processes, benefiting from this approach by reducing development and design cycle time, include: Creation of analysis models for the Aerodynamic discipline; Vehicle to ground interface development; Documentation development for the vehicle assembly.
Redmon, John W.↗
Low loss fiber-coupled volumetric interconnects fabricated via direct laser writing
Photonic integrated circuits (PICs) are vital for high-speed data transmission. However, optical routing is limited in PICs composed of only one or a few stacked planes. Further, coupling losses must be low in deployed systems. Previously, we developed the subsurface controllable refractive index via beam exposure (SCRIBE) technique to write accurate 3D gradient refractive index (GRIN) profiles within a mesoporous silica scaffold. Here, we apply SCRIBE to fabricate low loss, broadband, polarization insensitive, fiber-coupled, single-mode volumetric interconnects that include waveguides traversing arbitrary 3D paths. By seamlessly integrating mode-matching subsurface lenses and GRIN waveguide tapers, calibrating for positional writing errors, implementing multipass exposure, automating alignment, and switching to antireflection coated fibers, we reduced the insertion loss for a fiber-PIC-fiber interconnect from 50 to 2.14 dB, or 1.47 dB, excluding the fiber array’s loss. Further, we establish an upper bound of 0.45 dB loss per coupler. We report quality factors of 27,000 and 77,000 and bending losses of 6 and 3 dB/cm for 15 and 30 µm radii microrings, respectively. We also demonstrate Bézier escalators, polarization-rotating and polarization-splitting interconnects, and a seven-channel 25 µm pitch volumetric interconnect. The SCRIBE platform presents a clear path toward realizing 3D PICs with unique functionality.
Optics↗