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All sourcesNASA NTRSDOE OSTI
NASA NTRSDate not supplied

Inflatable Softgoods Design of an Articulating Crew Transfer Tunnel

Future NASA exploration plans call for lunar and Martian surface systems that form a base camp of multiple, pressurized elements. These discrete components, including habitats and pressurized rovers, require interoperability to meet the Artemis Accords and standard docking systems to physically connect elements together. A pressurized, articulating crew transfer tunnel can be used between a rover and habitat to enable shirt-sleeve transfer of crew and cargo, saving valuable crew time and resources. While transfer tunnels have been described in the past, this work details the design of a structural softgoods system that has compliant capability through a proposed docking range of motion. The inflatable softgoods design is based on a zero-hoop stress shape, known as a Taylor surface, that is stacked and truncated to form a unique and flexible configuration. Analytical, non-linear models have been developed to examine and predict the behavior of the structure, and material testing was used to determine the properties that were used in the model. Finally, a sub-scale test article was constructed using the baseline design and pressurized testing is in work. Additional full-scale testing is planned for future years to fully demonstrate the capability of the system.

Tunnel↗
NASA NTRS1980

Cell module and fuel conditioner

Measurements of stack height changes with temperature and cell material characteristics were made. Stack 559 was assembled and components were fabricated for 560, 561, and 562. Stack 425 was transferred from the parallel DOE program and installed in the OS/IES simulation loop for mechanical and electrical testing. Construction and preliminary checkout of the 2 kW test facility was completed and design and procurement of the 8 kW test facility was initiated. The fuel conditioning subsystem design continued to evolve and the state points for the current design were calculated at full and part load conditions. Steam reforming catalyst activity tests were essentially completed and aging tests and CO shift converter tests were initiated.

Hoover, D. Q., Jr.↗
NASA NTRS2017

Generating Land Surface Reflectance for the New Generation of Geostationary Satellite Sensors with the MAIAC Algorithm

The latest generation of geostationary satellite sensors, including the GOES-16/ABI and the Himawari 8/AHI, provide exciting capability to monitor land surface at very high temporal resolutions (5-15 minute intervals) and with spatial and spectral characteristics that mimic the Earth Observing System flagship MODIS. However, geostationary data feature changing sun angles at constant view geometry, which is almost reciprocal to sun-synchronous observations. Such a challenge needs to be carefully addressed before one can exploit the full potential of the new sources of data. Here we take on this challenge with Multi-Angle Implementation of Atmospheric Correction (MAIAC) algorithm, recently developed for accurate and globally robust applications like the MODIS Collection 6 re-processing. MAIAC first grids the top-of- atmosphere measurements to a fixed grid so that the spectral and physical signatures of each grid cell are stacked (“remembered”) over time and used to dramatically improve cloud/shadow/snow detection, which is by far the dominant error source in the remote sensing. It also exploits the changing sun-view geometry of the geostationary sensor to characterize surface BRDF with augmented angular resolution for accurate aerosol retrievals and atmospheric correction. The high temporal resolutions of the geostationary data indeed make the BRDF retrieval much simpler and more robust as compared with sun-synchronous sensors such as MODIS. As a prototype test for the geostationary-data processing pipeline on NASA Earth Exchange (GEONEX), we apply MAIAC to process 18 months of data from Himawari 8/AHI over Australia. We generate a suite of test results, including the input TOA reflectance and the output cloud mask, aerosol optical depth (AOD), and the atmospherically-corrected surface reflectance for a variety of geographic locations, terrain, and land cover types. Comparison with MODIS data indicates a general agreement between the retrieved surface reflectance products. Furthermore, the geostationary results satisfactorily capture the movement of clouds and variations in atmospheric dust/aerosol concentrations, suggesting that high quality land surface and vegetation datasets from the advanced geostationary sensors can help complement and improve the corresponding EOS products.

geostationary satellite sensors↗
NASA NTRS1980

Improvement and scale-up of the NASA Redox storage system

A preprototype 1.0 kW redox system (2 kW peak) with 11 kWh storage capacity was built and integrated with the NASA/DOE photovoltaic test facility at NASA Lewis. This full function redox system includes four substacks of 39 cells each (1/3 cu ft active area) which are connected hydraulically in parallel and electrically in series. An open circuit voltage cell and a set of rebalance cells are used to continuously monitor the system state of charge and automatically maintain the anode and cathode reactants electrochemically in balance. Recent membrane and electrode advances are summarized and the results of multicell stack tests of 1 cu ft are described.

Reid, M. A.↗
NASA NTRS1984

A Kosloff/Basal method, 3D migration program implemented on the CYBER 205 supercomputer

Conventional finite difference migration has relied on approximations to the acoustic wave equation which allow energy to propagate only downwards. Although generally reliable, such approaches usually do not yield an accurate migration for geological structures with strong lateral velocity variations or with steeply dipping reflectors. An earlier study by D. Kosloff and E. Baysal (Migration with the Full Acoustic Wave Equation) examined an alternative approach based on the full acoustic wave equation. The 2D, Fourier type algorithm which was developed was tested by Kosloff and Baysal against synthetic data and against physical model data. The results indicated that such a scheme gives accurate migration for complicated structures. This paper describes the development and testing of a vectorized, 3D migration program for the CYBER 205 using the Kosloff/Baysal method. The program can accept as many as 65,536 zero offset (stacked) traces.

Pyle, L. D.↗
NASA NTRS1989

A position sensitive detector for EUV remote sensing

The authors describe a photon-counting extreme ultraviolet (EUV) detector system used in a rocket-borne spectroscopic instrument for remote sensing of upper atmospheric composition and temperature. The detector uses a KBr coated microchannel plate (MCP) Z stack in combination with a wedge-and-strip image readout system. Three separate detector fields of view are used to sense the Earth dayglow spectrum (980 A to 1040 A, and 1300 A to 1360 A) and the solar EUV spectrum (250 A to 1400 A). The authors demonstrate high gain (2 x 107), tight pulse-height distribution (35 percent FWHM), and a spatial resolution of about 35 microns FWHM (full width at half maximum), which is the highest resolution for a wedge-and-strip anode MCP detector flown to date. The background, image linearity, and flat-field performance are discussed. Raw spectra from the rocket flight are also presented.

Siegmund, O. H. W.↗
NASA NTRS2023

ECS Artemis II Upgrades

The National Aeronautics and Space Administration (NASA) actively works to further the expectations of space exploration and research. NASA has been able to develop innovative technology and methods that has allowed for continued discovery and innovation. NASA is in the midst of work for the Artemis mission, which is to return to the moon in an effort to prepare for future Mars exploration. After the successful launch of Artemis I last November, our sights have shifted to Artemis II, which is set to launch next year and bring humans into the lunar orbit for the first time in over fifty years. Artemis II will be the first crewed mission for the program and will represent another step forward in our mission to advance our knowledge of the universe around us. From there, the Artemis program will move onto building a permanent site on the moon that will allow us to eventually reach Mars. During my time at NASA, I was able to work with the NE-XF Branch, also known as the Environmental and Life Support Systems Branch. I specifically worked with the Environmental Control Systems (ECS) team. During my time here, construction on the system in the Vehicle Assembly Building (VAB) and at Launchpad 39B have been progressing at full force. ECS is used to provide processed and purged air at specific temperatures, pressures, and humidity’s to fulfill requirements necessary to support Orion and the SLS. While the Pad has been undergoing upgrades from the original Artemis I configuration, the VAB has a completely new ECS very similar to it. While both systems have been undergoing upgrades, we have been able to transition into testing the systems as we prepare for stacking in the VAB early next year. My role has allowed me to learn about how the systems work and function through walkdowns and visits out to both the Pad and the VAB. I’ve been able to see firsthand how the system operates and have learned how the system affects the vehicle. I’ve been able to shadow my mentor, my coworkers, and COMET operators to oversee the construction efforts of the system along with the testing of the software and the system itself. I even was able to aid in testing at the console myself at Pad 39B. Additionally, I am also revising and reviewing displays for Artemis IV that will be used to remotely control parts of the system. Eventually these displays will be used to support the future of Artemis.

Monique Toon↗
NASA NTRS2019

Fractional Polarization of Extragalactic Sources in the 500 deg 2 SPTpol Survey

We study the polarization properties of extragalactic sources at 95 and 150 GHz in the SPTpol 500 deg 2 survey. We estimate the polarized power by stacking maps at known source positions, and correct for noise bias by subtracting the mean polarized power at random positions in the maps. We show that the method is unbiased using a set of simulated maps with similar noise properties to the real SPTpol maps. We find a flux-weighted mean-squared polarization fraction 〈p 2 〉 = [8.9 ± 1.1] × 10 -4 at 95 GHz and [6.9 ± 1.1] × 10 -4 at 150 GHz for the full sample. This is consistent with the values obtained for a subsample of active galactic nuclei. For dusty sources, we find 95 per cent upper limits of 〈p 2 〉95 < 16.9 × 10 -3 and 〈p 2 〉150 < 2.6 × 10 -3 . We find no evidence that the polarization fraction depends on the source flux or observing frequency. The 1σ upper limit on measured mean-squared polarization fraction at 150 GHz implies that extragalactic foregrounds will be subdominant to the CMB E and B mode polarization power spectra out to at least ℓ ≲ 5700 (ℓ ≲ 4700) and ℓ ≲ 5300 (ℓ ≲ 3600), respectively, at 95 (150) GHz.

Nikhel Gupta↗
NASA NTRS2005

Solid Freeform Fabrication of Composite-Material Objects

Composite solid freeform fabrication (C-SFF) or composite layer manufacturing (CLM) is an automated process in which an advanced composite material (a matrix reinforced with continuous fibers) is formed into a freestanding, possibly complex, three-dimensional object. In CLM, there is no need for molds, dies, or other expensive tooling, and there is usually no need for machining to ensure that the object is formed to the desired net size and shape. CLM is a variant of extrusion-type rapid prototyping, in which a model or prototype of a solid object is built up by controlled extrusion of a polymeric or other material through an orifice that is translated to form patterned layers. The second layer is deposited on top of the first layer, the third layer is deposited on top of the second layer, and so forth, until the stack of layers reaches the desired final thickness and shape. The elements of CLM include (1) preparing a matrix resin in a form in which it will solidify subsequently, (2) mixing the fibers and matrix material to form a continuous pre-impregnated tow (also called "towpreg"), and (3) dispensing the pre-impregnated tow from a nozzle onto a base while moving the nozzle to form the dispensed material into a patterned layer of controlled thickness. When the material deposited into a given layer has solidified, the material for the next layer is deposited and patterned similarly, and so forth, until the desired overall object has been built up as a stack of patterned layers. Preferably, the deposition apparatus is controlled by a computer-aided design (CAD) system. The basic CLM concept can be adapted to the fabrication of parts from a variety of matrix materials. It is conceivable that a CLM apparatus could be placed at a remote location on Earth or in outer space where (1) spare parts are expected to be needed but (2) it would be uneconomical or impractical to store a full inventory of spare parts. A wide variety of towpregs could be prepared and stored on spools until needed. Long-shelf-life towpreg materials suitable for such use could include thermoplastic-coated carbon fibers and metal-coated SiC fibers. When a spare part was needed, the part could be fabricated by CLM under control by a CAD data file; thus, the part could be built automatically, at the scene, within hours or minutes.

Wang, C. Jeff↗
NASA NTRS1975

Performance of full size metallic and RSI thermal protection systems in a Mach 7 environment

The integrity and reusability of three flight-weight metallic and RSI thermal protection systems, designed for the Shuttle entry environment, have been demonstrated. Each model successfully survived over 23 entry thermal cycles without serious degradation. The metallic systems were more tolerant of the hostile environment and provided a higher degree of reusability than did the RSI. Thermal expansion slip joints of the metallic TPS successfully prevented hot gas ingress to the substructure. The RSI demonstrated high damage tolerance and field repairs increased its reusability. Heat-transfer tests to further assess RSI gap heating indicate that stacked tile orientations may impose a penalty on tile thickness. Parameters influencing RSI impingement heating were determined, and the heating data were correlated.

Bohon, H. L.↗
NASA NTRS2020

The Atacama Cosmology Telescope: arcminute-resolution maps of 18,000 square degrees of the microwave sky from ACT 2008-2018 data combined with Planck

This paper presents a maximum-likelihood algorithm for combining sky maps with disparate sky coverage, angular resolution and spatially varying anisotropic noise into a single map of the sky. We use this to merge hundreds of individual maps covering the 2008–2018 ACT observing seasons, resulting in by far the deepest ACT maps released so far. We also combine the maps with the full Planck maps, resulting in maps that have the best features of both Planck and ACT: Planck’s nearly white noise on intermediate and large angular scales and ACT’s high-resolution and sensitivity on small angular scales. The maps cover over 18 000 square degrees, nearly half the full sky, at 100, 150 and 220 GHz. They reveal 4 000 optically-confirmed clusters through the Sunyaev Zel’dovich effect (SZ) and 18 500 point source candidates at > 5σ, the largest single collection of SZ clusters and millimeter wave sources to date. The multi-frequency maps provide millimeter images of nearby galaxies and individual Milky Way nebulae, and even clear detections of several nearby stars. Other anticipated uses of these maps include, for example, thermal SZ and kinematic SZ cluster stacking, CMB cluster lensing and galactic dust science. The method itself has negligible bias. However, due to the preliminary nature of some of the component data sets, we caution that these maps should not be used for precision cosmological analysis. The maps are part of ACT DR5, and will be made available on LAMBDA no later than three months after the journal publication of this article, along with an interactive sky atlas.

Sigurd Naess↗
NASA NTRS2000

SEM Characterization of Extinguished Grains from Plasma-Ignited M30 Charges

M30 propellant grains that had been ignited in interrupted closed bomb experiments were characterize by scanning electron microscopy (SEM). Previous chemical analysis of extinguished grains had given no indications of plasma-propellant chemical interactions that could explain the increased burning rates that had been previously observed in full-pressure closed bomb experiments. (This does not mean that there is no unique chemistry occurring with plasma ignition. It may occur very early in the ignition event and then become obscured by the burning chemistry.) In this work, SEM was used to look at grain morphologies to determine if there were increases in the surface areas of the plasma-ignited grains which would contribute to the apparent increase in the burning rate. Charges were made using 30 propellant grains (approximately 32 grams) stacked in two tiers and in two concentric circles around a plastic straw. Each grain was notched so that, when the grains were expelled from the bomb during extinguishment, it could be determined in which tier and which circle each grain was originally packed. Charges were ignited in a closed bomb by either a nickel wire/Mylar-capillary plasma or black powder. The bomb contained a blowout disk that ruptured when the pressure reached 35 MPa, and the propellant was vented into a collection chamber packed with polyurethane foam. SEM analysis of the grains fired with a conventional black powder igniter showed no signs of unusual burning characteristics. The surfaces seemed to be evenly burned on the exteriors of the grains and in the perforations. Grains that had been subjected to plasma ignition, however, had pits, gouges, chasms, and cracks in the surfaces. The sides of the grains closest to the plasma had the greatest amount of damage, but even surfaces facing the outer wall of the bomb had small pits. The perforations contained gouges and abnormally burned regions (wormholes) that extended into the web. The SEM photos indicated that a grain from the top tier, which was farther away from the plasma ignition source, sustained more plasma-induced damage to the perforations and the web than did the grains on the bottom tier.

Kinkennon, A.↗
NASA NTRS2014

MERRA Analytic Services: Meeting the Big Data Challenges of Climate Science Through Cloud-enabled Climate Analytics-as-a-service

Climate science is a Big Data domain that is experiencing unprecedented growth. In our efforts to address the Big Data challenges of climate science, we are moving toward a notion of Climate Analytics-as-a-Service (CAaaS). We focus on analytics, because it is the knowledge gained from our interactions with Big Data that ultimately produce societal benefits. We focus on CAaaS because we believe it provides a useful way of thinking about the problem: a specialization of the concept of business process-as-a-service, which is an evolving extension of IaaS, PaaS, and SaaS enabled by Cloud Computing. Within this framework, Cloud Computing plays an important role; however, we it see it as only one element in a constellation of capabilities that are essential to delivering climate analytics as a service. These elements are essential because in the aggregate they lead to generativity, a capacity for self-assembly that we feel is the key to solving many of the Big Data challenges in this domain. MERRA Analytic Services (MERRAAS) is an example of cloud-enabled CAaaS built on this principle. MERRAAS enables MapReduce analytics over NASAs Modern-Era Retrospective Analysis for Research and Applications (MERRA) data collection. The MERRA reanalysis integrates observational data with numerical models to produce a global temporally and spatially consistent synthesis of 26 key climate variables. It represents a type of data product that is of growing importance to scientists doing climate change research and a wide range of decision support applications. MERRAAS brings together the following generative elements in a full, end-to-end demonstration of CAaaS capabilities: (1) high-performance, data proximal analytics, (2) scalable data management, (3) software appliance virtualization, (4) adaptive analytics, and (5) a domain-harmonized API. The effectiveness of MERRAAS has been demonstrated in several applications. In our experience, Cloud Computing lowers the barriers and risk to organizational change, fosters innovation and experimentation, facilitates technology transfer, and provides the agility required to meet our customers' increasing and changing needs. Cloud Computing is providing a new tier in the data services stack that helps connect earthbound, enterprise-level data and computational resources to new customers and new mobility-driven applications and modes of work. For climate science, Cloud Computing's capacity to engage communities in the construction of new capabilies is perhaps the most important link between Cloud Computing and Big Data.

Data Analytics↗
NASA NTRSDate not supplied

Ab-Initio Study of Stacking Fault Segregation Behavior in Ni-based Superalloys at High Temperatures

Ni-based superalloys demonstrate extraordinary creep properties compared to traditional metallic systems due to the formation of L12 (γ’) precipitates. Despite experimental evidence of alloying element segregation to the stacking faults, prior ab-initio efforts indicated repulsion of Nb from superlattice intrinsic stacking faults (SISFs) . Due to the importance of this element in key strengthening mechanisms, we developed a new technique to account for multi-component segregation behavior at temperature combining ab-initio molecular dynamics (AIMD) and Monte-Carlo (MC) simulations. Using this technique, we replicated experimentally observed segregation behavior of Nb, Co, and Ti to the SISF in L12 (Figure 1). Furthermore, we investigated the co-segregation behaviors of individual pairs of alloying elements to determine the interaction effects which lead to this segregation behavior in the full alloy system. By simulating the reduced-chemistry models using our approach, we reconciled previous ab-initio calculations demonstrating repulsion of Nb from the SISF and the experimentally observed segregation behavior.

Molecular Dynamics↗
NASA NTRSDate not supplied

Development and Validation of a High-Vacuum Thermal Conductivity Testbed for Aerospace Interface Materials

Spacecraft thermal margins depend on the temperature penalty of installed interfaces, yet catalog conductivity omits bondline thickness, mating surfaces, preload, and environment. The Testbed for Advanced Interface Materials in Vacuum (TAIMV) addresses this engineering-data gap by converting ambient/vacuum temperature fields from a four-coupon stack into quantities usable in spacecraft thermal models. Its 17-node steady-state model resolves axial conduction, parasitic fixture paths, grease-filled contact, radiation, and ambient convection. Four monolithic checks gave axial heat-rate ratios of 0.90–1.02, and Braycote calibration self-recovery gave 2.20% casewise mean absolute percentage error (MAPE) and 2.85% maximum difference. With transferable fixture terms frozen, Krytox LVP tested cross-material transfer against a manufacturer-derived external relation. The six Krytox cases gave 2.28% MAPE, 5.10% maximum difference, and full-field residual root-mean-square values of 0.553 °C ambient and 1.306 °C vacuum. Installed-joint resistance spanned 6.39–7.15 × 10⁻⁴ m²·K/W for Braycote and 4.09–4.49 × 10⁻⁴ m²·K/W for Krytox, corresponding to 2.33–6.66 K per modeled interface over the tested heat-flux range. TAIMV therefore supplies directly usable installed-joint resistance and conductance, plus apparent installed conductivity and explicitly model-conditioned grease conductivity/contact terms.

heat transfer↗
NASA NTRS1980

Improvement and scale-up of the NASA Redox storage system

A preprototype full-function 1.0 kW Redox system (2 kW peak) with 11 kW storage capacity has been built and integrated with the NASA/DOE photovoltaic test facility. The system includes four substacks of 39 cells each (1/3 sq ft active area) which are connected hydraulically in parallel and electrically in series. An open circuit voltage cell and a set of rebalance cells are used to continuously monitor the system state of charge and automatically maintain the anode and cathode reactants electrochemically in balance. Technological advances in membrane and electrodes and results of multicell stack tests are reviewed.

Reid, M. A.↗
NASA NTRSDate not supplied

Solid-state Architecture Batteries for Enhanced Rechargeability and Safety (SABERS) Beyond Li-Ion: Technology to Enable Sustainable Electric Aviation

All-electric and hybrid electric aerovehicle concepts face numerous technical barriers prior to their introduction into the consumer marketplace in order to meet sustainable aviation goals. One of the primary barriers to overcome is developing an energy dense storage system capable of meeting the rigorous aerospace safety and performance criteria. Additionally, the electric aviation market requires that the batteries be fabricated in a sustainable manner with materials that are readily available and abundant within the U.S. to ensure there are no supply chain issues during manufacturing. The performance metrics to enable electric aviation are at least two times greater than those of electric ground vehicles. Furthermore, inherently non-flammable batteries are essential for safe operation of commercial electric aerovehicles. The SABERS concept proposes a battery that meets the key performance criteria through development of a solid-state architecture battery utilizing high-capacity sulfur-selenium cathode and lithium metal anode. The combination of sulfur and selenium offers a balanced energy-to-power density ratio, which can be tailored to the specific application by altering the stoichiometric ratios of sulfur to selenium. The hybrid cathode has been developed by implementing NASA patented holey graphene technology as a highly conductive, ultra-lightweight electrode scaffold. A solid-state electrolyte has been used as a safe, non-flammable replacement to the highly flammable liquid organic electrolytes currently used in SOA lithium-ion batteries. This solid-state lithium-sulfur/selenium cell will be designed into a serial stacking configuration to enable dense packaging of the battery cells. The serial stacking configuration is termed a bipolar stack, which has the advantages of reducing overall cell weight, simplifying the interfaced connections for the cell, and minimizing the cooling requirements. Lastly, optimization of battery components will occur through a robust and rigorous combination of various computational modeling techniques covering multiple length scales. The expected result will be a fully solid-state battery with operational temperatures up to 150 °C which provides the required energy density, discharge rates, and inherent safety to meet the strict aerospace mission performance criteria. This poster summarizes recent results from battery component optimization to scale-up production of full SABERS pouch cells.

Urban Air Mobility (UAM) Vehicles↗
NASA NTRSDate not supplied

SIBatt-3D: In-Space/On-Surface 3D Printing of Sodium Ion Batteries from ISRU Materials

Constructed more than 20 years ago, the International Space Station’s primary power system originally used nickel-hydrogen batteries with a lifetime of 6.5 years, until NASA began the process of replacing them in 2016 with lithium-ion batteries with a lifetime of 10 years. The demanding and costly process was accomplished after four flights of the Japanese H-II Transfer Vehicle cargo spacecraft (with a cost of about $10,000 per pound of payload), and 13 different astronauts conducting 14 spacewalks. Besides utilization in the ISS, rechargeable batteries are present in many space applications: they are installed in exploration robots, life support systems and in portable communication devices, to mention some. In this context, this project is focused on the in-space manufacturing of shape-conformable batteries using in-situ resources, and aims to address the NASA’s gaps related to the development of next generation of energy storage devices (TX03), as well as in-space manufacturing and in-situ resource utilization (TX07). The proposed work also tackles the HEOMD’s objectives targeting the in-space additive manufacturing (AM) from Lunar/Martian materials (regolith as AM feedstock) to reinvigorate America’s Human Space Exploration Program (SPD-1). This project is in direct alignment with the STMD’s objectives to demonstrate in-space autonomous manufacturing and assembly of complete systems by 2030, and to enable humans to live and explore in space and on planetary surfaces by 2040 thanks to in-space habitation, infrastructure development and in-situ resource utilization (ST1 and ST5). Manufacturing of shape conformable batteries directly in-space and using in-situ resources would also contribute to reducing the payload weight and volume (TX12) for future missions, thus reducing risk for long term Mars missions where rapid resupply is logistically infeasible. Nowadays, commercial batteries consist of stacked two-dimensional (2D) sheets, which are only manufactured in restricted geometries (cylindrical and coin cell). Evolving from conventional 2D, complex 3D battery architectures have been proven to increase the electrochemical active surface area and ion diffusion path, leading to improved areal energy density and power performance. This tendency was illustrated in our recent in-depth modeling studies by simulating a classical Ragone plot exhibiting the energy-power relationship. Our team demonstrated through modeling that a complex gyroidal 3D printed battery architecture exhibits significantly improved power performances (>150% at the current density of 6C; full discharge in 10 minutes) in comparison to a traditional 3D printed planar geometry. Motivated by these results and as the fabrication of intricate 3D battery design is only possible experimentally thanks to the geometric freedom offered by additive manufacturing (AM), our team has already initiated leveraging thermoplastic material extrusion at the laboratory scale. While 3D printing of batteries is relatively recent (2013), it has witnessed a growing interest during the last recent years, as next-generation shape-conformable 3D batteries can be co-designed with the system. Consequently, dead-volume and mass brought from Earth are minimized, in addition to improved battery performance, in alignment with the aforementioned NASA’s objectives. Further, while this project is specifically dedicated to batteries, it lends itself towards the maturation of in-space manufacturing via 3D printing using in-situ resources, stated in HEOMD and STMD goals.

In-Space Manufacturing↗