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All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Upcycling Mixed Spent Ni-Lean Cathodes into Ni-Rich Polycrystalline Cathodes

Sustainable battery recycling is vital for conserving resources and reducing environmental impacts. Current open- and closed-loop recycling strategies often focus on recovering individual components, making the reuse of mixed cathode materials a complex challenge. Meanwhile, the research on upcycling has been limited to using pristine cathode feedstocks and virgin materials for synthesis. Here, to address this issue, we present an upcycling approach for spent Ni-lean mixed cathode materials that integrate an upcycling hydrometallurgical recycling process with traditional hydrometallurgical methods. This strategy achieves a utilization of 92.31 mol % of recycled materials, enabling the regeneration of Ni-rich cathode materials while significantly reducing the reliance on virgin resources. The regenerated 83Ni cathode materials demonstrate physical properties comparable to those produced from virgin materials. Electrochemical evaluations using single-layer pouch cells show that both recycled and virgin cathodes exhibit initial specific capacity close to 201.1 mAh/g and maintain approximately 88 % capacity retention after 500 cycles. Additionally, 2Ah cells confirmed these findings, delivering 85 % capacity retention after about 900 cycles. Techno-economic analysis demonstrates notable environmental benefits, including reductions in greenhouse gas emissions and energy consumption, achieving 232.75 MJ/kg of product, which is 8.6 % lower than traditional methods and comparable to direct upcycling. Furthermore, the upcycling hydrometallurgical recycling process generates the highest profit, proving its economic viability. This scalable and versatile process is adaptable to varying transition metal compositions, facilitating a closed-loop recycling system that bridges mixed spent cathodes with next-generation cathode materials, and offers a sustainable solution for managing waste battery materials.

Hydrometallurgical recycling↗
NASA NTRSDate not supplied

Design and Applications of Tethered Spacecraft Simulators

Small, tethered spacecraft, or space tugs, are a promising space capability. They can be deployed on tethers and used for a wide variety of in-space activities; a large portion of which fall under in-space servicing, assembly, manufacturing (ISAM) functions. This includes functions such as structural mating and assembly, servicing, proximity operations, capture, docking, mating, and relocation. However, there is a great deal of work to be done to raise the Technology Readiness Level (TRL) of the capabilities needed to fully realize these capabilities. The Flat Floor Robotics Lab (FFRL) at NASA’s Marshall Spaceflight Center (MSFC) has been working on space tug development for several years. The eponymous floor is 44 by 86 feet, made from a self-leveling epoxy. This creates an extremely smooth surface that air bearings can float on with very little friction, creating a simulation of zero gravity in a two-dimensional plane. The lab has several platforms of various sizes that act as vehicle simulators for testing sensors, control algorithms, mechanisms, etc. One of these platforms is a small spacecraft simulator, which can be tethered to simulate a space tug. In the last several months, the FFRL team has been working with MSFC’s welding group to conduct a laser beam welding demonstration on air bearing platforms. This demo is utilizing a space tug simulator to fly up to a floating weld platform, where two parts are clamped together and laser welded. The space tug simulator has an air bearing to provide float, as well as several actuated air thrusters to provide propulsion and make the simulator maneuverable. Currently, flights of this simulator are completed by a human operator. An RF hand controller sends signals to both actuate and fire three sets of thrusters on the simulator. This makes any maneuvers of the space tug highly subject to human error, and operators must have dedicated practice time before being able to perform maneuvers with any sufficient reliability. For the current laser welding demonstration, human operated performance is sufficient, but future implementations of in-space welding and other ISAM efforts will require higher precision, reliability, and autonomy. MSFC has funded a project that will allow a small team in the FFRL to develop the next generation of space tug simulator, which will be automated. Closed loop control will allow a user to command a position, or set of positions, that the simulator will be able to “fly” to on its own. This Maneuverable Automated Tethered Spacecraft (MATS) simulator will have configurable design, to allow a variety of payloads and mission configurations to be demonstrated on the air bearing floor. This will be an invaluable test bed for low and mid TRL advancement for space tether mission subsystems, such as more advanced demonstrations of in-space welding. Once one MATSS is constructed and demonstrated effectively, several more can be built, enabling more advanced tether missions; Electric Sail test beds, sensor arrays, and other science-enabling missions. This paper will detail the design and test of the FFRL’s MATS simulator, including efforts to establish closed loop control and autonomous capabilities. It will also detail use cases for this technology, and how it will further develop both develop science and exploration missions.

Space Tethers↗
NASA NTRS2004

Stardust Dynamic Science at Wild 2: First Look

The Dynamic Science investigation on the STARDUST mission has been described previously. The data delivered by the STARDUST Project is multifold, but basically it consists of radio Doppler data from the Deep Space Network (DSN) and attitude control data (ACS) from the spacecraft. Doppler data were successfully recorded by JPL's Navigation System (closed-loop data) and also by its Radio Science System (open-loop data) at DSN stations DSS43 near Canberra Australia and at DSS14 at Goldstone California. Attitude control data were also successfully delivered to the Dynamic Science Team. Here we describe a preliminary analysis of the data. Beyond a closest approach distance of 150 km, a Doppler detection of a the Wild 2 nucleus mass was not expected. The current best estimate of the closest approach distance is 236.4 km, and as expected, any mass signal in the Doppler data is hopelessly buried in the noise. We have attempted to fit the data to a mass model with no success. However, analysis of the Doppler data and the ACS data for particle impacts on the spacecraft's Whipple shields is in progress, and will be reported at the meeting. The DSS43 closed-loop Doppler residuals are plotted as a function of time from the current best estimate of the time of Wild 2 closest approach, 2 January 2004, 19:43:11.7 UTC, Earth-receive time at the station.

Anderson, J. D.↗
NASA NTRS2003

Structured Uncertainty Bound Determination From Data for Control and Performance Validation

This report attempts to document the broad scope of issues that must be satisfactorily resolved before one can expect to methodically obtain, with a reasonable confidence, a near-optimal robust closed loop performance in physical applications. These include elements of signal processing, noise identification, system identification, model validation, and uncertainty modeling. Based on a recently developed methodology involving a parameterization of all model validating uncertainty sets for a given linear fractional transformation (LFT) structure and noise allowance, a new software, Uncertainty Bound Identification (UBID) toolbox, which conveniently executes model validation tests and determine uncertainty bounds from data, has been designed and is currently available. This toolbox also serves to benchmark the current state-of-the-art in uncertainty bound determination and in turn facilitate benchmarking of robust control technology. To help clarify the methodology and use of the new software, two tutorial examples are provided. The first involves the uncertainty characterization of a flexible structure dynamics, and the second example involves a closed loop performance validation of a ducted fan based on an uncertainty bound from data. These examples, along with other simulation and experimental results, also help describe the many factors and assumptions that determine the degree of success in applying robust control theory to practical problems.

Lim, Kyong B.↗
DOE OSTI2020

Accelerating Large-Format Metal Additive Manufacturing: How Controls R&D is Driving Speed, Scale, and Efficiency

This article highlights work at Oak Ridge National Laboratory’s Manufacturing Demonstration Facility to develop closed-loop, feedback control for laser-wire based Directed Energy Deposition, a form of metal Big Area Additive Manufacturing (m-BAAM), a process being developed in partnership with GKN Aerospace specifically for the production of Ti-6Al-4V pre-forms for aerospace components. A large-scale structural demonstrator component is presented as a case-study in which not just control, but the entire 3D printing workflow for m-BAAM is discussed in detail, including design principles for large-format metal AM, toolpath generation, parameter development, process control, and system operation, as well as post-print net-shape geometric analysis and finish machining. In terms of control, a multi-sensor approach has been utilized to measure both layer height and melt pool size, and multiple modes of closed-loop control have been developed to manipulate process parameters (laser power, print speed, deposition rate) to control these variables. Layer height control and melt pool size control have yielded excellent local (intralayer) and global (component-level) geometry control, and the impact of melt pool size control in particular on thermal gradients and material properties is the subject of continuing research. Further, these modes of control have allowed the process to advance to higher deposition rates (exceeding 7.5 lb/hr), larger parts (1-meter scale), shorter build times, and higher overall efficiency. The control modes are examined individually, highlighting their development, demonstration, and lessons learned, and it is shown how they operate concurrently to enable the printing of a large-scale, near net shape Ti-6Al-4V component.

Gibson, Brian↗
NASA NTRS2011

Enceladus and Europa: How Does Hydrothermal Activity Begin at the Surface?

The question of how the surface hydrothermal activity (e.g., eruptive plumes and heat flow) is initiated can be addressed within the frame-work of our "Perrier Ocean" model. This model delivers the necessary heat and chemicals to support the heat flow and plumes observed by Cassini in Enceladus' South Polar Region. The model employs closed-loop circulation of water from a sub-surface ocean. The ocean is the main reservoir of heat and chemicals, including dissolved gases. As ocean water moves up toward the surface, pressure is re-duced and gases exsolve forming bubbles. This bub-bly mixture is less dense than the icy crust and the buoyant ocean-water mixture rises toward the surface. Near the surface, heat and chemicals, including some volatiles, are delivered to the chambers in which plumes form and also to shallow reservoirs that keep the surface ice "warm". (Plume operations, per se, are as described by Schmidt et al. and Postberg et al. and are adopted by us.) After transferring heat, the water cools, bubbles contract and dissolve, and the mixture is now relatively dense. It descends through cracks in the crust and returns to the ocean. Once the closed-loop circulation has started it is self-sustaining. Loss of water via the erupting plumes is relatively negligible compared to the amount needed to maintain the heat flow.We note that the activity described herein for the the "Perrier-Ocean" model could, a priori, apply to all small icy bodies that sheltered an interior ocean at some point in their history.

Enceladus↗
NASA NTRS2003

Multiphase flow and phase change in microgravity: Fundamental research and strategic research for exploration of space

NASA is preparing to undertake science-driven exploration missions. The NASA Exploration Team's vision is a cascade of stepping stones. The stepping-stone will build the technical capabilities needed for each step with multi-use technologies and capabilities. An Agency-wide technology investment and development program is necessary to implement the vision. The NASA Exploration Team has identified a number of areas where significant advances are needed to overcome all engineering and medical barriers to the expansion of human space exploration beyond low-Earth orbit. Closed-loop life support systems and advanced propulsion and power technologies are among the areas requiring significant advances from the current state-of-the-art. Studies conducted by the National Academy of Science's National Research Council and Workshops organized by NASA have shown that multiphase flow and phase change play a crucial role in many of these advanced technology concepts. Lack of understanding of multiphase flow, phase change, and interfacial phenomena in the microgravity environment has been a major hurdle. An understanding of multiphase flow and phase change in microgravity is, therefore, critical to advancing many technologies needed. Recognizing this, the Office of Biological and Physical Research (OBPR) has initiated a strategic research thrust to augment the ongoing fundamental research in fluid physics and transport phenomena discipline with research especially aimed at understanding key multiphase flow related issues in propulsion, power, thermal control, and closed-loop advanced life support systems. A plan for integrated theoretical and experimental research that has the highest probability of providing data, predictive tools, and models needed by the systems developers to incorporate highly promising multiphase-based technologies is currently in preparation. This plan is being developed with inputs from scientific community, NASA mission planners and industry personnel. The fundamental research in multiphase flow and phase change in microgravity is aimed at developing better mechanistic understanding of pool boiling and ascertaining the effects of gravity on heat transfer and the critical heat flux. Space flight experiments conducted in space have shown that nucleate pool boiling can be sustained under certain conditions in the microgravity environment. New space flight experiments are being developed to provide more quantitative information on pool boiling in microgravity. Ground-based investigations are also being conducted to develop mechanistic models for flow and pool boiling. An overview of the research plan and roadmap for the strategic research in multiphase flow and phase change as well as research findings from the ongoing program will be presented.

Singh, Bhim S.↗
NASA NTRS2015

Atmosphere Resource Recovery and Environmental Monitoring

Atmosphere Resource Recovery and Environmental Monitoring (ARREM) is a project focused on evolving existing and maturing emerging 'closed loop' atmosphere revitalization (AR) life support systems that produce clean, breathable air for crewmembers, and developing a suite of low mass, low power environmental monitors to detect and measure air- and waterborne constituents and contaminants. The objective is to improve reliability and efficiency, reduce mass and volume, and increase recovery of oxygen from carbon dioxide created by human metabolism from 43% to greater than 90%. The technology developments under ARREM are vital to extending human space missions from low-Earth orbit like the International Space Station to destinations deeper into space such as Mars where dependency on Earth for resupply of maintenance items and critical life support elements such as water and oxygen is not possible. The primary goal of the ARREM project is to demonstrate that systems meet the more stringent performance parameters for deep space exploration and are compatible with other systems within closed loop life support through a series of integrated tests performed in an environmental test chamber capable of simulating human metabolic activities and measuring systems outputs.

Roman, Monsi↗
DOE OSTI2024

In‐mold rheology and automated process control for injection molding of recycled polypropylene

Abstract Manufacturing plastic parts with secondary feedstocks has risen to the forefront of importance in recent years. However, the variation in molecular weight and rheology of secondary feedstock can lead to inconsistent part quality. This work evaluates the effectiveness of a novel closed‐loop adaptive process control system that adjusts nozzle pressure in response to in‐mold pressure data. Five different recycled polypropylene blends, with a broad distribution of flow properties, were evaluated to determine the effectiveness of the control system at reducing processing variation. The experimental results show that the process control strategy reduced the variation within the mold, as seen by in‐mold pressure curves and calculated in‐mold viscosity values. Additionally, the parameters that control the automated process adjustments were investigated, showing the importance of optimization. The analysis of the correlation between in‐mold rheology and mechanical properties showed a slight variation in the mechanical properties and parts weight with a coefficient of variation of under 5%. Overall, the results demonstrate the ability of pressure‐controlled molding and automated viscosity adjustment to reduce the variability when molding a secondary feedstock. Highlights Pressure‐controlled injection molding of recycled polypropylene. Automated closed‐loop adaptive process control methodology. Methodology resulted in a reduction in pressure variation during molding. Changes in mechanical properties and in‐mold viscosity were investigated. Results show the potential of pressure‐controlled molding at reducing variation.

Krantz, Joshua↗
NASA NTRS2010

Advanced Catalysts for the Ambient Temperature Oxidation of Carbon Monoxide and Formaldehyde

The primary applications for ambient temperature carbon monoxide (CO) oxidation catalysts include emergency breathing masks and confined volume life support systems, such as those employed on the Shuttle. While Hopcalite is typically used in emergency breathing masks for terrestrial applications, in the 1970s, NASA selected a 2% platinum (Pt) on carbon for use on the Shuttle since it is more active and also more tolerant to water vapor. In the last 10-15 years there have been significant advances in ambient temperature CO oxidation catalysts. Langley Research Center developed a monolithic catalyst for ambient temperature CO oxidation operating under stoichiometric conditions for closed loop carbon dioxide (CO2) laser applications which is also advertised as having the potential to oxidize formaldehyde (HCHO) at ambient temperatures. In the last decade it has been discovered that appropriate sized nano-particles of gold are highly active for CO oxidation, even at sub-ambient temperatures, and as a result there has been a wealth of data reported in the literature relating to ambient/low temperature CO oxidation. In the shorter term missions where CO concentrations are typically controlled via ambient temperature oxidation catalysts, formaldehyde is also a contaminant of concern, and requires specially treated carbons such as Calgon Formasorb as untreated activated carbon has effectively no HCHO capacity. This paper examines the activity of some of the newer ambient temperature CO and formaldehyde (HCHO) oxidation catalysts, and measures the performance of the catalysts relative to the NASA baseline Ambient Temperature Catalytic Oxidizer (ATCO) catalyst at conditions of interest for closed loop trace contaminant control systems.

Nalette, Tim↗
DOE OSTI2024

Cost Competitive Process of Battery Grade Oxides Preparation from Aged LIBS

The increasing demand for lithium-ion batteries (LIBs ) is driving development of advanced recycling and refining methods. In this project, new cathode active materials are prepared from recycled lithium battery materials and subsequently electrochemically evaluated in coin cells. In detail, scrap LIBs were mechanically processed into a metal rich black mass, then reductive acid leached into an aqueous metal solution, and finally high-purity metal hydroxide precursor materials were prepared by selective electrochemical flow precipitation. Closed-loop LIB recycling into active electrode materials will enable US manufacturers to break their reliance on foreign sources of critical materials. For example, electroextraction process used here has potential to significantly reduce chemical & water use as compared to traditional metallurgic techniques. To this end, electroextracted materials refined from used batteries were collected and processed to be tested as precursor cathode active material (pCam).During this project ,samples of high-purity recycled NMC hydroxide (~2kg each) were received from Nth Cycle. In the first received batch some impurities like cadmium, calcium, and sodium are present in quantities that would negatively impact battery performance. Nth Cycle indicated that the impurities such as cadmium are present due to poor battery separation and co-shredding of NiCd batteries with with LIB. Cadmium was not present in the two subsequent batches as Nth Cycle processed cadmium free black mass. Thus, effective recycled battery sorting is critical to closed-loop LIB recycling into active electrode materials.

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2025

Cost Competitive Process of Battery Grade Oxides Preparation from Aged LIBS

The increasing demand for lithium-ion batteries (LIBs) is driving development of advanced recycling and refining methods. In this project, new cathode active materials are prepared from recycled lithium battery materials and subsequently electrochemically evaluated in coin cells. In detail, scrap LIBs were mechanically processed into a metal rich black mass, then reductive acid leached into an aqueous metal solution, and finally high-purity metal hydroxide precursor materials were prepared by selective electrochemical flow precipitation. Closed-loop LIB recycling into active electrode materials will enable US manufacturers to break their reliance on foreign sources of critical materials. For example, electroextraction process used here has potential to significantly reduce chemical & water use as compared to traditional metallurgic techniques. To this end, electroextracted materials refined from used batteries were collected and processed to be tested as precursor cathode active material (pCam). During this project , samples of high-purity recycled NMC hydroxide (~2 kg each) were received from Nth Cycle. In the first received batch some impurities like cadmium, calcium, and sodium are present in quantities that would negatively impact battery performance. Nth Cycle indicated that the impurities such as cadmium are present due to poor battery separation and co-shredding of NiCd batteries with with LIB. Cadmium was not present in the two subsequent batches as Nth Cycle processed cadmium free black mass. Thus, effective recycled battery sorting is critical to closed-loop LIB recycling into active electrode materials.

25 ENERGY STORAGE↗
DOE OSTI2022

Advanced Hydropower and PSH Capacity Expansion Modeling (Final Report on HydroWIRES D1 Improvements to Capacity Expansion Modeling)

Hydropower and pumped-storage hydropower (PSH) have played a key role in providing flexible, low-carbon electricity to the U.S. electricity system for over a century. As variable generation (VG) deployment increases the demand for flexible, dispatchable generation, it is important to use all available methods for understanding how hydropower and PSH interfaces with VG in a future low-carbon grid. Capacity expansion models (CEMs) of electricity systems are often used to study future electricity scenarios, but these tools often have difficulty representing site- and technology-details of hydropower and PSH due to limited spatial, temporal, or process resolution. This report demonstrates a set of model advancements to improve hydropower and PSH representations in CEMs and other models that consider hydropower and PSH's role in electricity systems. Model advancements include new data integration to define closed-loop PSH resource availability and cost, along with site-level parameterizations of existing PSH capacity and energy storage specifications. Shifting energy across seasons for both hydropower and PSH is explored to demonstrate the potential value of long-duration storage. New representations of hydropower upgrades offer opportunities to increase dispatchability, add pumps, or independently add capacity or energy depending on what is most valuable. New model structures and data are demonstrated individually and in combination to observe their impact on model results and provide initial insights into what is most important for analysts, electricity system planners, and hydropower decision-makers to consider when assessing future roles of hydropower. Improving flexibility of existing hydropower assets has the potential to reduce CO 2 emissions through complementing VG technologies and/or improve electricity system economics by reducing the need to deploy higher-cost systems. Large-scale energy storage is also shown to provide opportunities for balancing seasonal differences in VG, particularly solar photovoltaics (PV). Initial analysis with a new closed-loop PSH resource and cost dataset also demonstrate the potential for new PSH deployment to offer new grid flexibility opportunities. Future analysis and modeling of hydropower's role in the U.S. and other electricity systems could include methodological improvements based on those discussed here along with sensitivity analysis to better represent current and future potential hydropower and PSH flexibility. Improvements to geospatial and site-level data can further improve the understanding of how hydropower and PSH can be upgraded and operated in response to future electricity system needs. This work lays the groundwork to use advanced planning models to explore the range of roles hydropower and PSH can play in the grid of the future.

13 HYDRO ENERGY↗
NASA NTRS1993

The Middeck Active Control Experiment (MACE)

The Middeck Active Control Experiment (MACE) is a NASA In-Step and Control Structure Interaction (CSI) Office funded Shuttle middeck experiment. The objective is to investigate the extent to which closed-loop behavior of flexible spacecraft in zero-gravity (0-g) can be predicted. This prediction becomes particularly difficult when dynamic behavior during ground testing exhibits extensive suspension and direct gravity coupling. On-orbit system identification and control reconfiguration is investigated to improve performance which would otherwise be limited due to errors in prediction. The program is presently in its preliminary design phase with launch expected in the summer of 1994. The MACE test article consists of three attitude control torque wheels, a two axis gimballing payload, inertial sensors and a flexible support structure. With the acquisition of a second payload, this will represent a multiple payload platform with significant structural flexibility. This paper presents on-going work in the areas of modelling and control of the MACE test article in the zero and one-gravity environments. Finite element models, which include suspension and gravity effects, and measurement models, derived from experimental data, are used as the basis for Linear Quadratic Gaussian controller designs. Finite element based controllers are analytically used to study the differences in closed-loop performance as the test article transitions between the 0-g and 1-g environments. Measurement based controllers are experimentally applied to the MACE test article in the 1-g environment and achieve over an order of magnitude improvement in payload pointing accuracy when disturbed by a broadband torque disturbance. The various aspects of the flight portion of the experiment are also discussed.

Miller, David W.↗
NASA NTRS2010

Assessing Space Exploration Technology Requirements as a First Step Towards Ensuring Technology Readiness for International Cooperation in Space Exploration

Advancing critical and enhancing technologies is considered essential to enabling sustainable and affordable human space exploration. Critical technologies are those that enable a certain class of mission, such as technologies necessary for safe landing on the Martian surface, advanced propulsion, and closed loop life support. Others enhance the mission by leading to a greater satisfaction of mission objectives or increased probability of mission success. Advanced technologies are needed to reduce mass and cost. Many space agencies have studied exploration mission architectures and scenarios with the resulting lists of critical and enhancing technologies being very similar. With this in mind, and with the recognition that human space exploration will only be enabled by agencies working together to address these challenges, interested agencies participating in the International Space Exploration Coordination Group (ISECG) have agreed to perform a technology assessment as an important step in exploring cooperation opportunities for future exploration mission scenarios. "The Global Exploration Strategy: The Framework for Coordination" was developed by fourteen space agencies and released in May 2007. Since the fall of 2008, several International Space Exploration Coordination Group (ISECG) participating space agencies have been studying concepts for human exploration of the moon. They have identified technologies considered critical and enhancing of sustainable space exploration. Technologies such as in-situ resource utilization, advanced power generation/energy storage systems, reliable dust resistant mobility systems, and closed loop life support systems are important examples. Similarly, agencies such as NASA, ESA, and Russia have studied Mars exploration missions and identified critical technologies. They recognize that human and robotic precursor missions to destinations such as LEO, moon, and near earth objects provide opportunities to demonstrate the technologies needed for Mars mission. Agencies see the importance of assessing gaps and overlaps in their plans to advance technologies in order to leverage their investments and enable exciting missions as soon as practical. They see the importance of respecting the ability of any agency to invest in any technologies considered interesting or strategic. This paper will describe the importance of developing an appropriate international strategy for technology development and ideas for effective mechanisms for advancing an international strategy. This work will both inform and be informed by the development of an ISECG Global Exploration Roadmap and serve as a concrete step forward in advancing the Global Exploration Strategy.

Laurini, Kathleen C.↗
DOE OSTI2025

Digital twin framework for PIP-II linac: AI-driven multi-scale modeling from ion source to 800 MeV

The PIP-II superconducting linac at Fermilab is designed to deliver multi-megawatt proton beams for neutrino physics and other high-intensity applications. To expedite commissioning and enhance operational reliability, we have developed an EPICS-based data flow framework that seamlessly integrates digital twins (DT) with physical twins (PT). These digital twins comprise high-fidelity beam dynamics models or data-driven surrogate models connected to their physical counterparts through real-time diagnostics and advanced machine-learning algorithms.Central to this framework is Linac_Gen, an accelerated simulation tool that incorporates convolutional neural networks, random forests, and genetic algorithms to provide up to a tenfold speedup in optimizing the accelerator geometry model. An EPICS translator layer ensures interoperability by efficiently mapping lattice parameters across diverse simulation platforms.Our EPICS-based framework supports multiple operational modes—monitoring, passive learning, closed-loop control, and online learning—covering the entire machine lifecycle. By leveraging HPC resources and multi-objective optimization techniques, the digital twin enables adaptive trajectory correction, real-time fault detection, and predictive modeling of beam stability. This comprehensive approach paves the way for robust, high-intensity operation and data-driven accelerator R&D at Fermilab.

Pathak, Abhishek [Fermilab]↗
NASA NTRS2012

Variable Vector Countermeasure Suit (V2Suit) for Space Habitation and Exploration

The "Variable Vector Countermeasure Suit (V2Suit) for Space Habitation and Exploration" is a visionary system concept that will revolutionize space missions by providing a platform for integrating sensors and actuators with daily astronaut intravehicular activities to improve human health and performance. The V2Suit uses control moment gyroscopes (CMGs) within a miniaturized module placed on body segments to provide a "viscous resistance" during movements and a countermeasure to the sensorimotor and musculoskeletal adaptation performance decrements that manifest themselves while living and working in microgravity and during gravitational transitions during long-duration spaceflight, including post-flight recovery and rehabilitation. Through an integrated design, system initialization, and control systems approach the V2Suit is capable of generating this "viscous resistance" along an arbitrarily specified direction of "down." When movements are made, for example, parallel to that "down" direction a resistance is applied, and when the movement is perpendicular to that direction no resistance is applied. The V2Suit proposes to be a countermeasure to this spaceflight-related adaptation and de-conditioning and the unique sensorimotor characteristics associated with living and working in 0-G, which are critical for future long-duration space missions.This NIAC Phase I project focused on detailing several aspects of the V2Suit concept, including human-system integration, system architecture, computer aided design (CAD) modeling, and closed-loop simulation and analysis. In addition, early-stage breadboard prototyping of several aspects of the V2Suit system modules enabled characterization of expected performance and identified areas for further research and development to enable operational implementation of the V2Suit. In particular, potential challenges with integration of commercial-off-the-shelf components were identified. The key enabler for operational use and adoption of the V2Suit is a low-profile body worn form factor that does not interfere with normal, everyday movements and interfaces adequately with the body as to provide the generated gyroscopic torque for the perceptions of movement with a "viscous resistance." These aspects were investigated through mockups using a life-size mannequin, and through body attachment mechanisms on the breadboard prototype. Through the evaluation and investigation of commercially-available components, as well as an identification of desirable form factors, CAD models of the V2Suit modules were developed. These models included all of the required elements and spin motors, flywheel masses, gimbal motors, slip rings, inertial measurement units, motor controllers, and the required mounting brackets/hardware and cabling. The configuration and orientation of the control moment gyroscopes (CMGs) was specified according to results from the modeling, simulation and analysis. Two revisions of the CAD model were investigated through closed-loop simulation of the CMGs, and their ability to generate a resultant reaction force during movement and null undesirable torques due to changes in the direction of the angular momentum vector as a result of the normal body movements.

space missions↗
DOE OSTI2025

Machine Learning-Based Process Control for Injection Molding of Recycled Polypropylene

The increased interest in artificial intelligence in manufacturing has driven the adoption of machine learning to optimize processes and improve efficiency. A key challenge in injection molding is the variability of recycled materials, which affects part quality and processing stability. This study presents a novel closed-loop process control approach for injection molding, leveraging machine learning to adaptively predict processing inputs and quality outcomes. The methodology was tested on five blends of recycled polypropylene (rPP), using artificial neural networks (ANNs), linear regression, and polynomial regression to model the relationships between material properties and process parameters. The dataset was split 80/20 into training and testing sets. The ANN model was implemented using TensorFlow and Keras, with six hidden layers of 32 neurons per layer, ReLU activation, and an Adam optimizer. Empirical tuning and early stopping were used to optimize performance and prevent overfitting. Predictions were evaluated based on mean absolute error (MAE), mean squared error (MSE), and percentage error. The results showed that yield stress, ultimate elongation, and part weight were accurately predicted within a 5% error for linear and polynomial regression models and within a 10% error for the ANN. However, modulus predictions were less reliable, with errors of ~11% for ANN and linear regression and ~40% for polynomial regression, reflecting the inherent variability of this property in rPP blends. Predictions of processing inputs had errors ranging from 3% to 25%, depending on the model and response variable. No single modeling approach was consistently superior across all responses, highlighting the complexity of the relationship between material properties, process parameters, and quality metrics. Overall, the work demonstrates that closed-loop process control, powered by machine learning, can effectively predict key quality parameters in injection molding of recycled materials. The proposed approach can improve process stability and material utilization, facilitating increased adoption of sustainable materials.

Krantz, Joshua↗