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All sourcesNASA NTRSDOE OSTI
NASA NTRS1989

The design of a commercial space infrastructure

Space Services and Logistics, Inc. represents the complete engineering design of a technically and financially viable commercial space company. The final proposal offers an economically sound program of space vehicles and systems designed to substantially affect a variety of space markets and produce a vertically integrated structure within the next 20 years. Throughout this design process, particular stress has been placed on attaining the highest possible levels of safety and reliability. The final program financial design requires a considerable initial outlay, but promises a relatively quick return on invested capital, culminating in large annual profits by the end of the 20-year scope of the cost outlook. The overall design has been extensively researched and was primarily driven by the present and near-term projected market demands for services uniquely or competitively offered only by space-oriented operations. Heretofore, available capabilities, rather than these market demands, have determined the degree and type of commercial market access. Removing this limitation through extensive use of modularity and reconfigurability allows the company to gear itself to the market, while still remaining extremely competitive with existing systems. The markets identified as lucrative, and that have governed much of the design requirements, are: low-cost launch services to LEO over a wide range of payload masses and inclinations; upper stage payload delivery from LEO to GEO; manned space operations and human transport to and from orbit; EVA assembly and maintenance of large space structures; satellite servicing and repair by both humans and telerobotic operations; a line of customized satellites designed for extended life and capable of reconfiguration or technology upgrade on orbit; small-scale microgravity experimentation and manufacturing supported by spacecraft retrieval capabilities for experimental specimens and manufactured goods; and a full-range of payload integration, testing, design, and support services before launch and once in orbit.

Source record↗
NASA NTRS2009

Low Cost Rapid Response Spacecraft, (LCRRS): A Research Project in Low Cost Spacecraft Design and Fabrication in a Rapid Prototyping Environment

The Low Cost Rapid Response Spacecraft (LCRRS) is an ongoing research development project at NASA Ames Research Center (ARC), Moffett Field, California. The prototype spacecraft, called Cost Optimized Test for Spacecraft Avionics and Technologies (COTSAT) is the first of what could potentially be a series of rapidly produced low-cost satellites. COTSAT has a target launch date of March 2009 on a SpaceX Falcon 9 launch vehicle. The LCRRS research system design incorporates use of COTS (Commercial Off The Shelf), MOTS (Modified Off The Shelf), and GOTS (Government Off The Shelf) hardware for a remote sensing satellite. The design concept was baselined to support a 0.5 meter Ritchey-Chretien telescope payload. This telescope and camera system is expected to achieve 1.5 meter/pixel resolution. The COTSAT team is investigating the possibility of building a fully functional spacecraft for $500,000 parts and $2,000,000 labor. Cost is dramatically reduced by using a sealed container, housing the bus and payload subsystems. Some electrical and RF designs were improved/upgraded from GeneSat-1 heritage systems. The project began in January 2007 and has yielded two functional test platforms. It is expected that a flight-qualified unit will be finished in December 2008. Flight quality controls are in place on the parts and materials used in this development with the aim of using them to finish a proto-flight satellite. For LEO missions the team is targeting a mission class requiring a minimum of six months lifetime or more. The system architecture incorporates several design features required by high reliability missions. This allows for a true skunk works environment to rapidly progress toward a flight design. Engineering and fabrication is primarily done in-house at NASA Ames with flight certifications on materials. The team currently employs seven Full Time Equivalent employees. The success of COTSATs small team in this effort can be attributed to highly cross trained engineering team. The engineers on the team are capable of functioning in two to three engineering disciplines which allows highly efficient interdisciplinary engineering collaboration. NASA Ames is actively proposing mission concepts to use the COTSAT platform to accomplish science. If the COTSAT team validates this approach, it will allow the possibility for remote sensing missions to produce a high science yield for minimal cost and reduced schedule. Another aim of this approach is to yield an accelerated pathway from a Phase A study to mission launch. Leaders in the aerospace industry have shown interest in this methodology. Several visits and tours have been given in the lab. Although the concept of low-cost development is initially met with skepticism from some within the prohibitive aerospace industry, the project's efforts have been highly praised for the accomplishments met within a limited time and budget. Overall the development has progressed tremendously well and the team is answering critical questions for current and future low-cost small satellite developments. COTSAT subsystems are not limited to a specific weight class and could be adapted to produce smaller platforms and to fit various launch vehicles.

Spremo, Stevan↗
NASA NTRS2002

Development of Face Gear Technology for Industrial and Aerospace Power Transmission

Tests of a 250 horsepower proof-of-concept (POC) split torque face gear transmission were completed by The Boeing Company in Mesa, Arizona, while working under a Defense Advanced Research Projects Agency (DARPA) Technology Reinvestment Program (TRP) This report provides a summary of these cooperative tests, which were jointly funded by Boeing and DARPA Design, manufacture and testing of the scaled-power TRP split torque gearbox followed preliminary evaluations of the concept performed early in the program The testing demonstrated the theory of operation for the concentric, tapered face gear assembly The results showed that the use of floating pinions in a concentric face gear arrangement produces a nearly even torque split The POC split torque tests determined that, with some improvements, face gears can be applied effectively in a split torque configuration which yields significant weight, cost and reliability improvements over conventional designs.

Heath, Gregory F.↗
NASA NTRS1990

A Byzantine resilient processor with an encoded fault-tolerant shared memory

The memory requirements for ultra-reliable computers are expected to increase due to future increases in mission functionality and operating-system requirements. This increase will have a negative effect on the reliability and cost of the system. Increased memory size will also reduce the ability to reintegrate a channel after a transient fault, since the time required to reintegrate a channel in a conventional fault-tolerant processor is dominated by memory realignment time. A Byzantine Resilient Fault-Tolerant Processor with Fault-Tolerant Shared Memory (FTP/FTSM) is presented as a solution to these problems. The FTSM uses an encoded memory system, which reduces the memory requirement by one-half compared to a conventional quad-FTP design. This increases the reliability and decreases the cost of the system. The realignment problem is also addressed by the FTSM. Because any single error is corrected upon a read from the FTSM, a faulty channel's corrupted memory does not need realignment before reintegration of the faulty channel. A combination of correct-on-access and background scrubbing is proposed to prevent the accumulation of transient errors in the memory. With a hardware-implemented scrubber, the scrubbing cycle time, and therefore the memory fault latency, can be upper-bounded at a small value. This technique increases the reliability of the memory system and facilitates validation of its reliability model.

Butler, Bryan↗
NASA NTRS1987

Fracture mechanics concepts in reliability analysis of monolithic ceramics

Basic design concepts for high-performance, monolithic ceramic structural components are addressed. The design of brittle ceramics differs from that of ductile metals because of the inability of ceramic materials to redistribute high local stresses caused by inherent flaws. Random flaw size and orientation requires that a probabilistic analysis be performed in order to determine component reliability. The current trend in probabilistic analysis is to combine linear elastic fracture mechanics concepts with the two parameter Weibull distribution function to predict component reliability under multiaxial stress states. Nondestructive evaluation supports this analytical effort by supplying data during verification testing. It can also help to determine statistical parameters which describe the material strength variation, in particular the material threshold strength (the third Weibull parameter), which in the past was often taken as zero for simplicity.

Manderscheid, Jane M.↗
DOE OSTI2026

PVDeg: Enhancing Usability and AI-Driven Multi-Mechanism Degradation Modeling

PVDeg version 0.7.0, released in December 2025, introduced major enhancements to improve usability and performance. This update reorganized tutorials and tool notebooks to create a more intuitive experience, enabling users to easily follow and adapt workflows for their specific analyses. In addition to structural improvements, both the notebooks and core logic underwent significant optimization for efficiency, robustness, and style. These refinements were supported by new testing frameworks built on nbval and pytest, adherence to PEP8 standards, and extensive code refactoring, which collectively simplify onboarding for new developers. Looking ahead, version 0.8.0 will deliver advanced AI-driven capabilities. The primary focus is to further develop and automate the degradation workflow, designed to analyze PV module degradation across diverse locations and system configurations. By integrating large language models (LLMs) to scan literature and compile a comprehensive database of materials and degradation rates, this feature will enable modeling of multiple materials and mechanisms within a single, streamlined workflow. Users will be able to evaluate degradation impacts on different system architectures under varying environmental conditions, facilitating informed decisions on bill-of-materials optimization for specific deployment scenarios. These advancements position PVDeg as a powerful, user-friendly tool for accelerating PV reliability research and system design.

14 SOLAR ENERGY↗
NASA NTRS2012

Data Acquisition System Architecture and Capabilities At NASA GRC Plum Brook Station's Space Environment Test Facilities

Very large space environment test facilities present unique engineering challenges in the design of facility data systems. Data systems of this scale must be versatile enough to meet the wide range of data acquisition and measurement requirements from a diverse set of customers and test programs, but also must minimize design changes to maintain reliability and serviceability. This paper presents an overview of the common architecture and capabilities of the facility data acquisition systems available at two of the world?s largest space environment test facilities located at the NASA Glenn Research Center?s Plum Brook Station in Sandusky, Ohio; namely, the Space Propulsion Research Facility (commonly known as the B-2 facility) and the Space Power Facility (SPF). The common architecture of the data systems is presented along with details on system scalability and efficient measurement systems analysis and verification. The architecture highlights a modular design, which utilizes fully-remotely managed components, enabling the data systems to be highly configurable and support multiple test locations with a wide-range of measurement types and very large system channel counts.

Evans, Richard K.↗
NASA NTRS2014

Data Acquisition System Architecture and Capabilities at NASA GRC Plum Brook Station's Space Environment Test Facilities

Very large space environment test facilities present unique engineering challenges in the design of facility data systems. Data systems of this scale must be versatile enough to meet the wide range of data acquisition and measurement requirements from a diverse set of customers and test programs, but also must minimize design changes to maintain reliability and serviceability. This paper presents an overview of the common architecture and capabilities of the facility data acquisition systems available at two of the world's largest space environment test facilities located at the NASA Glenn Research Center's Plum Brook Station in Sandusky, Ohio; namely, the Space Propulsion Research Facility (commonly known as the B-2 facility) and the Space Power Facility (SPF). The common architecture of the data systems is presented along with details on system scalability and efficient measurement systems analysis and verification. The architecture highlights a modular design, which utilizes fully-remotely managed components, enabling the data systems to be highly configurable and support multiple test locations with a wide-range of measurement types and very large system channel counts.

Evans, Richard K.↗
DOE OSTI2020

Four-Switch Buck-Boost Converter Based on Model Predictive Control with Smooth Mode Transition Capability

Four-switch buck-boost converter supports both voltage step-up and step-down functionalities, but it suffers from mode transfer challenge that would need reliable mode detection when designed to operate in multi different modes. In this paper, a novel control method based on model predictive current control is proposed for such converter with inherent smooth mode transfer capability without extra design on mode detection and transfer scheme. Modulator and mode detection are replaced by an optimization process through cost function. This largely simplifies the design and makes it easily implemented. Therefore, seamless transfer between buck and boost modes is achieved with many other system level benefits. Simulation and experimental results are provided to verify the effectiveness of proposed method for the four-switch buck-boost converter.

42 ENGINEERING↗
NASA NTRS2000

In Space Nuclear Power as an Enabling Technology for Deep Space Exploration

Deep Space Exploration missions, both for scientific and Human Exploration and Development (HEDS), appear to be as weight limited today as they would have been 35 years ago. Right behind the weight constraints is the nearly equally important mission limitation of cost. Launch vehicles, upper stages and in-space propulsion systems also cost about the same today with the same efficiency as they have had for many years (excluding impact of inflation). Both these dual mission constraints combine to force either very expensive, mega systems missions or very light weight, but high risk/low margin planetary spacecraft designs, such as the recent unsuccessful attempts for an extremely low cost mission to Mars during the 1998-99 opportunity (i.e., Mars Climate Orbiter and the Mars Polar Lander). When one considers spacecraft missions to the outer heliopause or even the outer planets, the enormous weight and cost constraints will impose even more daunting concerns for mission cost, risk and the ability to establish adequate mission margins for success. This paper will discuss the benefits of using a safe in-space nuclear reactor as the basis for providing both sufficient electric power and high performance space propulsion that will greatly reduce mission risk and significantly increase weight (IMLEO) and cost margins. Weight and cost margins are increased by enabling much higher payload fractions and redundant design features for a given launch vehicle (higher payload fraction of IMLEO). The paper will also discuss and summarize the recent advances in nuclear reactor technology and safety of modern reactor designs and operating practice and experience, as well as advances in reactor coupled power generation and high performance nuclear thermal and electric propulsion technologies. It will be shown that these nuclear power and propulsion technologies are major enabling capabilities for higher reliability, higher margin and lower cost deep space missions design to reliably reach the outer planets for scientific exploration.

Sackheim, Robert L.↗
NASA NTRS1981

Distributed processing on the Space Shuttle - A case study

A Power Extension Package (PEP) has been designed to provide additional electrical power and energy during Shuttle sortie missions. The considered investigation was conducted to determine the most suitable allocation of PEP monitoring and control functions between the Orbiter's existing (centralized) Systems Management General Purpose Computer and an embedded PEP processor. PEP monitoring and control functions are examined, and a configuration definition is considered, taking into account the 'functional migration' process, function allocation criteria, and candidate functional configurations. A trade study is conducted, giving attention to an assessment of four candidate configurations. Assessment factors are related to cost, development risk, aspects of reliability and safety, PEP design complexity, PEP/STS integration complexity, flight operations, and launch/landing site operations. A thorough (subjective) assessment of the PEP system life cycle indicates substantial benefits from a distributed processing approach.

Schoonmaker, P. B.↗
DOE OSTI2025

Effect of 3D-printed surface textures on wear mechanism in 3-body abrasion of soil

This study systematically investigates the enhancement of wear resistance in 3D printed surface textures through both experimental and theoretical approaches. Three distinct surface morphologies (Smooth Surface, Surface with uniformly distributed Pits, and Surface with uniformly distributed Bumps) were fabricated using High-Impact Polystyrene, where the meso-scale textures were precisely controlled through the 3D printing process. Wear behavior was evaluated using a 3-body wear tester in an abrasive particle environment, analyzing the influence of surface textures under various operating conditions. Systematic wear tests revealed that optimally designed surface textures achieved a remarkable 77 % reduction in wear compared to the worst-performing sample. The wear mechanisms were comprehensively characterized through weight loss measurements, Scanning Electron Microscopy (SEM), and Energy Dispersive Spectroscopy (EDS) analyses, elucidating the surface morphology changes and their interaction with wear particles. Notably, the study identified how the geometric characteristics of surface textures influence the movement of wear particles and the distribution of contact stresses. Discrete element method simulations corroborated the experimental findings, providing theoretical validation for the enhanced wear resistance of the optimal structure. The high correlation between simulated wear patterns and experimental results validates the reliability of the proposed design methodology. In conclusion, these results demonstrate that 3D printed surface texturing offers a cost-effective and scalable approach to significantly improve wear resistance in engineering applications, presenting a practical alternative to conventional, high-cost surface engineering methods.

3-body abrasion↗
NASA NTRS2000

Variable Emissivity Through MEMS Technology

This paper discusses a new technology for variable emissivity (vari-e) radiator surfaces, which has significant advantages over traditional radiators and promises an alternative design technique for future spacecraft thermal control systems. All spacecraft rely on radiative surfaces to dissipate waste heat. These radiators have special coatings, typically with a low solar absorptivity and a high infrared-red emissivity, that are intended to optimize performance under the expected heat load and thermal sink environment. The dynamics of the heat loads and thermal environment make it a challenge to properly size the radiator and often require some means of regulating the heat rejection rate of the radiators in order to achieve proper thermal balance. Specialized thermal control coatings, which can passively or actively adjust their emissivity offer an attractive solution to these design challenges. Such systems would allow intelligent control of the rate of heat loss from a radiator in response to heat load and thermal environmental variations. Intelligent thermal control through variable emissivity systems is well suited for nano and pico spacecraft applications where large thermal fluctuations are expected due to the small thermal mass and limited electric resources. Presently there are three different types of vari-e technologies under development: Micro ElectroMechanical Systems (MEMS) louvers, Electrochromic devices, and Electrophoretic devices. This paper will describe several prototypes of micromachined (MEMS) louvers and experimental results for the emissivity variations measured on theses prototypes. It will further discuss possible actuation mechanisms and space reliability aspects for different designs. Finally, for comparison parametric evaluations of the thermal performances of the new vari-e technology and standard thermal control systems are presented in this paper.

Darrin, Ann Garrison↗
NASA NTRS2004

Advanced Subsonic Technology (AST) 22-Inch Low Noise Research Fan Rig Preliminary Design of ADP-Type Fan 3

This report presents results of the work completed on the preliminary design of Fan 3 of NASA s 22-inch Fan Low Noise Research project. Fan 3 was intended to build on the experience gained from Fans 1 and 2 by demonstrating noise reduction technology that surpasses 1992 levels by 6 dB. The work was performed as part of NASA s Advanced Subsonic Technology (AST) program. Work on this task was conducted in the areas of CFD code validation, acoustic prediction and validation, rotor parametric studies, and fan exit guide vane (FEGV) studies up to the time when a NASA decision was made to cancel the design, fabrication and testing phases of the work. The scope of the program changed accordingly to concentrate on two subtasks: (1) Rig data analysis and CFD code validation and (2) Fan and FEGV optimization studies. The results of the CFD code validation work showed that this tool predicts 3D flowfield features well from the blade trailing edge to about a chord downstream. The CFD tool loses accuracy as the distance from the trailing edge increases beyond a blade chord. The comparisons of noise predictions to rig test data showed that both the tone noise tool and the broadband noise tool demonstrated reasonable agreement with the data to the degree that these tools can reliably be used for design work. The section on rig airflow and inlet separation analysis describes the method used to determine total fan airflow, shows the good agreement of predicted boundary layer profiles to measured profiles, and shows separation angles of attack ranging from 29.5 to 27deg for the range of airflows tested. The results of the rotor parametric studies were significant in leading to the decision not to pursue a new rotor design for Fan 3 and resulted in recommendations to concentrate efforts on FEGV stator designs. The ensuing parametric study on FEGV designs showed the potential for 8 to 10 EPNdB noise reduction relative to the baseline.

Jeracki, Robert J.↗
NASA NTRS1976

Long life coolant pump technology

Design concepts were investigated to improve space system coolant pump technology to be suitable for mission durations of two years and greater. These design concepts included an improved bearing system for the pump rotating elements, consisting of pressurized conical bearings. This design was satisfactorily endurance tested as was a new prototype pump built using various other improved design concepts. Based upon an overall assessment of the results of the program it is concluded that reliable coolant pumps can be designed for three year space missions.

Source record↗
NASA NTRS1993

On the design of fault-tolerant robotic manipulator systems

Robotic systems are finding increasing use in space applications. Many of these devices are going to be operational on board the Space Station Freedom. Fault tolerance has been deemed necessary because of the criticality of the tasks and the inaccessibility of the systems to maintenance and repair. Design for fault tolerance in manipulator systems is an area within robotics that is without precedence in the literature. In this paper, we will attempt to lay down the foundations for such a technology. Design for fault tolerance demands new and special approaches to design, often at considerable variance from established design practices. These design aspects, together with reliability evaluation and modeling tools, are presented. Mechanical architectures that employ protective redundancies at many levels and have a modular architecture are then studied in detail. Once a mechanical architecture for fault tolerance has been derived, the chronological stages of operational fault tolerance are investigated. Failure detection, isolation, and estimation methods are surveyed, and such methods for robot sensors and actuators are derived. Failure recovery methods are also presented for each of the protective layers of redundancy. Failure recovery tactics often span all of the layers of a control hierarchy. Thus, a unified framework for decision-making and control, which orchestrates both the nominal redundancy management tasks and the failure management tasks, has been derived. The well-developed field of fault-tolerant computers is studied next, and some design principles relevant to the design of fault-tolerant robot controllers are abstracted. Conclusions are drawn, and a road map for the design of fault-tolerant manipulator systems is laid out with recommendations for a 10 DOF arm with dual actuators at each joint.

Tesar, Delbert↗
DOE OSTI2022

Generative Design for Resilience of Interdependent Network Systems

Abstract Interconnected complex systems usually undergo disruptions due to internal uncertainties and external negative impacts such as those caused by harsh operating environments or regional natural disaster events. To maintain the operation of interconnected network systems under both internal and external challenges, design for resilience research has been conducted from both enhancing the reliability of the system through better designs and improving the failure recovery capabilities. As for enhancing the designs, challenges have arisen for designing a robust system due to the increasing scale of modern systems and the complicated underlying physical constraints. To tackle these challenges and design a resilient system efficiently, this study presents a generative design method that utilizes graph learning algorithms. The generative design framework contains a performance estimator and a candidate design generator. The generator can intelligently mine good properties from existing systems and output new designs that meet predefined performance criteria while the estimator can efficiently predict the performance of the generated design for a fast iterative learning process. Case studies results based on synthetic supply chain networks and power systems from the IEEE dataset have illustrated the applicability of the developed method for designing resilient interdependent network systems.

Engineering↗
NASA NTRS1977

Extended performance electric propulsion power processor design study. Volume 1: Executive summary

Several power processor design concepts were evaluated and compared. Emphasis was placed on a 30cm ion thruster power processor with a beam supply rating of 2.2kW to 10kW. Extensions in power processor performance were defined and were designed in sufficient detail to determine efficiency, component weight, part count, reliability and thermal control. Preliminary electrical design, mechanical design, and thermal analysis were performed on a 6kW power transformer for the beam supply. Bi-Mod mechanical, structural, and thermal control configurations were evaluated for the power processor, and preliminary estimates of mechanical weight were determined. A program development plan was formulated that outlines the work breakdown structure for the development, qualification and fabrication of the power processor flight hardware.

Biess, J. J.↗