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All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Sustainable Electric Vehicle Batteries for a Sustainable World: Perspectives on Battery Cathodes, Environment, Supply Chain, Manufacturing, Life Cycle, and Policy

Abstract Li‐ion batteries (LIBs) can reduce carbon emissions by powering electric vehicles (EVs) and promoting renewable energy development with grid‐scale energy storage. However, LIB production and electricity generation still heavily rely on fossil fuels at present, resulting in major environmental concerns. Are LIBs as environmentally friendly and sustainable as expected at the current stage? In the past 5 years, a skyrocketing growth of the EV market has been witnessed. LIBs have garnered huge attention from academia, industry, government, non‐governmental organizations, investors, and the general public. Tremendous volumes of LIBs are already implemented in EVs today, with a continuing, exponential growth expected for the years to come. When LIBs reach their end‐of‐life in the next decades, what technologies can be in place to enable second‐life or recycling of batteries? Herein, life cycle assessment studies are examined to evaluate the environmental impact of LIBs, and EVs are compared with internal combustion engine vehicles regarding environmental sustainability. To provide a holistic view of the LIB development, this Perspective provides insights into materials development, manufacturing, recycling, legislation and policy, and beyond. Last but not least, the future development of LIBs and charging infrastructures in light of emerging technologies are envisioned.

36 MATERIALS SCIENCE↗
NASA NTRS2022

Working Toward A National Coordinated Soil Moisture Monitoring Network: Vision, Progress, and Future Directions

Soil moisture is a critical land surface variable, impacting the water, energy, and carbon cycles. While in situ soil moisture monitoring networks are still developing, there is no cohesive strategy or framework to coordinate, integrate, or disseminate these diverse data sources in a synergistic way that can improve our ability to understand climate variability at the national, state, and local levels. Thus, a national strategy is needed to guide network deployment, sustainable network operation, data integration and dissemination, and user-focused product development. The National Coordinated Soil Moisture Monitoring Network (NCSMMN) is a federally led, multi-institution effort that aims to address these needs by capitalizing on existing wide-ranging soil moisture monitoring activities, increasing the utility of observational data, and supporting their strategic application to the full range of decision-making needs. The goals of the NCSMMN are to 1) establish a national “network of networks” that effectively demonstrates data integration and operational coordination of diverse in situ networks; 2) build a community of practice around soil moisture measurement, interpretation, and application—a “network of people” that links data providers, researchers, and the public; and 3) support research and development (R&D) on techniques to merge in situ soil moisture data with remotely sensed and modeled hydrologic data to create user-friendly soil moisture maps and associated tools. The overarching mission of the NCSMMN is to provide coordinated high-quality, nationwide soil moisture information for the public good by supporting applications like drought and flood monitoring, water resource management, agricultural and forestry planning, and fire danger ratings.

C. Bruce Baker↗
DOE OSTI2021

LightMAT - Continuous fiber malleable thermoset composites with sub-1-minute dwell times; validation of impact performance and evaluation of the efficacy of the compression forming process (CRADA 409 Final Report)

In spite of carbon fiber composite materials’ significant impact on light-weighting, performance, and efficiency in the aerospace industry, adoption of these materials has been slow in high-volume industries such as automotive. Two major barriers to adoption are cost and cycle-time. Current approaches to thermoset composite part production are dependent on in-mold curing of thermosets which are not optimal for high volume, high throughput production due to limitations and inefficiencies associated with the in-mold cure itself. In addition, ancillary activities, such as transport and storage of shelf-life-limited uncured, or B-staged prepreg materials typically necessitate refrigerated transport and storage which significantly impacts the economic and energy costs associated with manufacturing. Furthermore, limited out-life means that trimmings cannot typically be used as they partially cure during initial production leading to high scrap rates (+20% is common). Finally, the need to cure in-mold drives cycle times to multiple minutes in the best cases, and 10’s of minutes to hours in most cases. Mallinda is developing polyimine malleable thermoset prepreg composite materials which have excellent mechanical properties (100 GPa tensile modulus, 2 GPA tensile strength, 2.4% elongation at break) and high operating temperatures (Tg>200°C). At scale, polyimine resins are commensurate in price with commodity epoxy resins. What distinguishes malleable thermoset prepreg from traditional thermoset prepreg materials, is that they are fully cured during Mallinda’s roll-to-roll production of prepreg laminate. This results in 5 key value-differentiating benefits. First, it simplifies manufacturing logistics by enabling ambient transportation and storage, and by significantly extending out-life and shelf-life almost indefinitely. Second, elimination of autoclave curing reduces the economic and energy costs to the customer. Third, scrap rates can be reduced as malleable thermoset prepreg materials are directly reusable. Fourth, the manufacturing consolidation step can be roughly 10x faster than traditional thermosets, because the resin is already cured. Parts can be made via compression forming by the application of heat and pressure to quickly vitrify and consolidate a multilayer part – easily leading to sub 3-minute cycle times (at lab scale we have demonstrated a 20 second dwell time, with room for further optimization). Finally, the closed-loop cradle-to-cradle solution-based recyclability of malleable thermoset composites can also contribute significantly to the future of sustainable lightweight materials. The focus of this project was the development, optimization and validation of malleable thermoset composite materials which exhibit manufacturing cycle times of 3-minute or less, high speed impact performance on par with incumbent technologies, and defect-free consolidation of 3 dimensional parts. Government funding is required on this project because Mallinda is a start-up company whose focus is the development and scale-up of the described technology for introduction to the transportation segment. Unlike incumbent industry players, Mallinda is bringing a completely new and highly relevant malleable thermoset technology to bear on the problem of high throughput composites. As a small business, Mallinda relies on a combination of government R&D funding and private capital to perform development work.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Continuous fiber malleable thermoset composites with sub-1-minute dwell times; validation of impact performance and evaluation of the efficacy of the compression forming process. CRADA Final Report

Mallinda is developing polyimine malleable thermoset prepreg composite materials which have excellent mechanical properties (100 GPa tensile modulus, 2 GPA tensile strength, 2.4% elongation at break) and high operating temperatures (Tg>200°C). At scale, polyimine resins are commensurate in price with commodity epoxy resins. What distinguishes malleable thermoset prepreg from traditional thermoset prepreg materials, is that they are fully cured during Mallinda’s roll-to-roll production of prepreg laminate. This results in 5 key value-differentiating benefits. First, it simplifies manufacturing logistics by enabling ambient transportation and storage, and by significantly extending out-life and shelf-life almost indefinitely. Second, elimination of autoclave curing reduces the economic and energy costs to the customer. Third, scrap rates can be reduced as malleable thermoset prepreg materials are directly reusable. Fourth, the manufacturing consolidation step can be roughly 10x faster than traditional thermosets, because the resin is already cured. Parts can be made via compression forming by the application of heat and pressure to quickly vitrify and consolidate a multilayer part – easily leading to sub 3-minute cycle times (at lab scale we have demonstrated a 20 second dwell time, with room for further optimization). Finally, the closed-loop cradle-to-cradle solution-based recyclability of malleable thermoset composites can also contribute significantly to the future of sustainable lightweight materials. The focus of this project was the development, optimization and validation of malleable thermoset composite materials which exhibit manufacturing cycle times of 3-minute or less, high speed impact performance on par with incumbent technologies, and defect-free consolidation of 3 dimensional parts.

36 MATERIALS SCIENCE↗
NASA NTRS2015

In-Space Manufacturing: Pioneering a Sustainable Path to Mars

In order to provide meaningful impacts to exploration technology needs, the In-Space Manufacturing (ISM) Initiative must influence exploration systems design now. In-space manufacturing offers: dramatic paradigm shift in the development and creation of space architectures; efficiency gain and risk reduction for low Earth orbit and deep space exploration; and "pioneering" approach to maintenance, repair, and logistics leading to sustainable, affordable supply chain model. In order to develop application-based capabilities in time to support NASA budget and schedule, ISM must be able to leverage the significant commercial developments, which requires innovative, agile collaborative mechanisms (contracts, challenges, SBIR's, etc.); and NASA-unique investments to focus primarily on adapting the technologies and processes to the microgravity environment. We must do the foundational work - it is the critical path for taking these technologies from lab curiosities to institutionalized capabilities: characterize, certify, institutionalize, design for Additive Manufacturing (AM). Ideally, International Space Station (ISS) U.S. lab rack or partial rack space should be identified for in-space manufacturing utilization in order to continue technology development of a suite of capabilities required for exploration missions, as well as commercialization on ISS.

Werkheiser, Niki↗
NASA NTRSDate not supplied

Beyond Fair: Engagement, Data Usability, and Open Community Productivity through the NASA Open Science Data Repository

The FAIR principle (findable, accessible, interoperable, and reusable) governs the storage and sharing of NASA space biology and health data[1]. These guiding principles maximize reuse of data and the reproducibility of scientific findings. The NASA Open Science Data Repository (OSDR; an expansion of NASA GeneLab) was built on the FAIR principles and houses over 500 studies and close to 1000 datasets from decades of space life sciences experiments. OSDR embodies the FAIR principles through data governance that includes mediated, embargoed, and fully open access data. The FAIR data governance principles were recently proposed to be expanded to encompass a FAIREST framework for assessing research data repositories (FAIR + Engagement, Social connections, and Trust)[2]. FAIREST emphasizes the importance of data repositories engaging with the scientific community and gaining the trust of researchers regarding data quality. Trust also refers to the TRUST principles developed for assessment of digital repositories: Transparency, Responsibility, User Focus, Sustainability, Technology[3]. We present the “Open Science for Life in Space” Analysis Working Groups (AWGs) as evidence regarding the power of engagement, social connections, and trust which has enhanced OSDR’s capabilities and productivity. AWG members engage in two main activities. One, members provide feedback on OSDR scientific standards for data ingestion, curation, and reuse (study, subject and assay metadata; processing pipelines; dataset formats and uniformed structures for machine-readability). Two, AWG members collaborate to mine-reuse OSDR data to conduct scientific analysis. With nearly 800 active members, the AWGs have resulted in 32 publications re-using OSDR data and contributed many papers in two major special issues in Cell (2020) and Nature (2024). AWGs also serve as networking groups, facilitate social connections between researchers at all levels of experience, and also have a social online ‘Forum’ used to keep members informed on projects and opportunities. This community-centric, productive, and trustworthy data culture has resulted in a broader effect with international space agencies, academics, and the commercial space sector wanting to submit their data to OSDR. Ten studies of Inspiration 4 data were recently publicly released by OSDR, as were some JAXA human data. Coming up soon in OSDR are data submissions from the European Space Agency, Virgin Galactic PIs, and SpaceX Polaris Dawn. A major benefit of OSDR is the array of standardized and uniformly formatted data (which was developed through AWG member consensus), from which visualization tools, analysis tools, and machine learning models can be built or trained. This talk will cover the Multi-Study Visualization Tool, the Environmental Data Application, RadLab, and a UCSF-NSF funded knowledge graph biomedical health discovery tool ‘SPOKE’ currently being integrated with OSDR. OSDR also provides training programs in bioinformatics and machine learning to improve the scientific community’s awareness of data availability and to boost their ability to perform data analysis. The increasing engagement of the scientific community and the public with technologies powered by artificial intelligence (AI) heightens the need for data analysis to be transparent. The AI for Life in Space initiative leverages the data products provided in OSDR to train AI models, with an emphasis on explainable and trustworthy AI, which would not be possible without FAIR data and metadata. Overall, here we will demonstrate the importance for NASA life sciences data repositories to adhere to the FAIREST framework, by providing examples and success stories from different aspects of OSDR.

data↗
DOE OSTI2022

Plant-based engineering for production of high-valued natural products

Plants are a unique source of complex specialized metabolites, many of which play significant roles in human society. In many cases, however, the availability of these metabolites from naturally occurring sources fails to meet current demands. Thus, there is much interest in expanding the production capacity of target plant molecules. Traditionally, plant breeding, chemical synthesis, and microbial fermentation are considered the primary routes towards large scale production of natural products. Here, in this paper, we explore the advances, challenges, and future of plant engineering as a complementary path. Although plants are an integral part of our food and agricultural systems and sustain an extensive array of chemical constituents, their complex genetics and physiology have prevented the optimal exploitation of plants as a production chassis. We highlight emerging engineering tools and scientific advances developed in recent years that have improved the prospects of using plants as a sustainable and scalable production platform. We also discuss technological limitations and overall economic outlook of plant-based production of natural products.

59 BASIC BIOLOGICAL SCIENCES↗
NASA NTRS2003

Records of our Early Biosphere Illuminate our Origins and Guide our Search for Life Beyond Earth

A scientific "mission of exploration to early Earth" will help us chart the distribution of life elsewhere. We must discriminate between attributes of biospheres that are universal versus those attributes that represent principally the outcomes of long-term survival specifically on Earth. In addition to the basic physics and chemistry of matter, the geologic evolution of rocky habitable planets and their climates might be similar elsewhere in the Universe. Certain key agents that drive long-term environmental change (e.g., stellar evolution, impacts, geothermal heat flow, tectonics, etc.) can help us to reconstruct ancient climates and to compare their evolution among populations of Earth- like planets. Early Earth was tectonically more active than today and therefore it exhaled reduced chemical species into the more oxidized surface environment at greater rates. This tectonic activity thus sustained oxidation-reduction reactions that provided the basis for the development of biochemical pathways that harvest chemical energy ("bioenergetics"). Most examples of bioenergetics today that extract energy by reacting oxidized and reduced chemicals in the environment were likely more pervasive among our microbial ancestors than are the presently known examples of photosynthesis. The geologic rock record indicates that, as early as 3.5 billion years ago (3.5 Ga), microbial biofilms were widespread within the coastal environments of small continents and tectonically unstable volcanic islands. Non oxygen-producing (non-oxygenic) photosynthesis preceded oxygenic photosynthesis, but all types of photosynthesis contributed substantially to the long-term increase in global primary biological productivity. Evidence of photosynthesis is tentative by 3.5 Ga and compelling by 2.7 Ga. Evidence of oxygenic photosynthesis is strong by 2.7 Ga and compelling by 2.3 Ga. These successive innovations transformed life from local communities that survived principally by catalyzing chemical equilibration to a globally dominant agent that created and sustained widespread chemical disequilibria in the environment and shallow crust. Major biogeochemical perturbations ca. 2.3 to 2.0 Ga, 1.3 Ga, and also 0.8 to 0.6 Ga, contributed to the irreversible oxidation of the global environment and perhaps also triggered evolutionary innovations (e.g., the development of multi-cellular biota) that became the foundations of our modern biosphere. Understanding the nature and timing of this ascent of life is crucial for discerning our o m beginnings. This understanding also empowers OUT search for the origins, evolution and distribution of life elsewhere in our solar system and beyond.

DesMarais, David J.↗
DOE OSTI2024

High-Burnup BWR LOCA Burst Analysis Framework Development and Demonstration

Nuclear power currently contributes approximately 20% of total electricity generation in the United States and more than 10% globally. Given the increasing reliance on nuclear energy to achieve our nation’s goal of reaching net-zero carbon emissions by 2050, there is significant pressure on the existing nuclear industry to extend plant operational licenses and improve efficiency. This is crucial as the existing nuclear fleet serves as a vital bridge until new light water and advanced reactors can be developed and deployed, bolstering the supply of carbon-free energy to meet domestic demands. Operational costs primarily consist of plant operation and maintenance and fuel costs, influenced by materials and reactor core designs. These factors, coupled with heavily subsidized renewable energy markets, create a challenging economic environment for the existing light water reactor fleet, as well as for new build projects. To address these economic challenges, the nuclear industry has developed a strategic blueprint aimed at enhancing nuclear power’s economic sustainability. Past initiatives, such as efforts to eliminate fuel failures by 2010 and reduce operating costs by 30% before 2020, have laid the groundwork. Optimizing core design parameters, including burnup limits and enrichment levels, can lengthen cycles, reduce outages, reduce batch reload batch fractions and spent fuel storage requirements, and lower maintenance and operating expenses, thereby enhancing economic viability. In the United States, boiling water reactors (BWRs) comprise approximately one-third of the fleet, although much of the research and development focus has traditionally been on pressurized water reactors (PWRs). Advances in modeling and simulation, particularly through the Nuclear Energy Advanced Modeling and Simulation (NEAMS) program, are crucial to the long-term viability of BWRs, just as they are for PWRs. A key research area of the high burnup/increased enriched fuel initiative is focused on addressing loss-of-coolant-accident (LOCA)-related issues. NEAMS has dedicated significant effort to enhancing tools to better support BWRs, with a current focus on showcasing the BWR framework for high-burnup LOCA analysis. This high-fidelity work will demonstrate a best estimate pin-by-pin high-burnup BWR LOCA analysis to assess full-core cladding rupture behavior. This modeling capability will help with better understanding and realistic evaluation of fuel fragmentation, relocation, and dispersal (FFRD) phenomena at BWRs, which then could be used to prevent FFRD at BWRs without penalizing operational parameters. In addition, the results of this work will help identify strategies to identify additional margins or to potentially limit cladding rupture through core design optimizations.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2020

Risk-Informed MultiPphysics BestEestimate Plus Uncertainties (BEPU) Application Development of RELAP5-3D Perturbation Model

The United States nuclear industry is facing a strong challenge to ensure maximum safety while enhancing economic benefit. Safety is a key parameter to all aspects related to light water reactor (LWR) nuclear power plants (NPPs), especially cost savings. Since the goal is to extend the lifetimes of these NPPs, the traditional deterministic safety concept may not guarantee a current economic asset. The Light Water Reactor Sustainability (LWRS) Program has been promoting a wide range of research and development (R&D) in this field to maximize the safety, economics, and performance of these NPPs through improved scientific understanding. One of the best practices to achieve this goal is to identify and optimize safety margins, which can lead to cost reduction. To do this, under the LWRS framework, the Risk-Informed Systems Analysis (RISA) Pathway will focus on the optimization of safety margin and minimization of uncertainties to ensure both safety and economics at the highest level. The RISA Pathway will provide enhanced capabilities for analyzing and characterizing LWR systems performance by developing and demonstrating methods, tools, and data to enable risk-informed margins management (RIMM). The goals of the RISA Pathway are twofold: (1) deploy the risk-informed tools and methods that enable better representation of safety margins and factors that contribute to cost and safety; and (2) conduct advanced risk assessment applications with industry to support margin management strategies that enable more cost-effective plant operation. The tools and methods provided by the RISA Pathway will support effective margin management for both active and passive safety systems, structures, and components (SSC) of an NPP. The tools and methods used in the RISA Pathway should have high confidence and highest technical maturity for and implementation to industry at its current setting. They should also have a capability to support risk-informed decision making for both probabilistic and deterministic elements of safety. The RISA Pathway will, therefore, perform a comprehensive assessment of verification and validation (V&V) status of RISA Toolkit to enhance credibility RISA Toolkit which be used by industry. This report summarizes RELAP5-3D development activities for best estimated and uncertainty (BEPU) capability to support ongoing RISA Pathway pilot projects for risk informed uncertainty quantification applications. Work scope includes (1) development of initial perturbation model for selected closure laws and (2) testing of suitable probability distribution functions (PDF) for the selected correlations. Developed BEPU modules are tested with selected separate effect cases and compared with conventional thermal-hydraulics model.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
NASA NTRSDate not supplied

Overview of NASA's RESOURCE (Resource Exploration and Science of OUR Cosmic Environment) Project

The RESOURCE(Resource Exploration and Science of OUR Cosmic Environment) project is supported by NASA’s SSERVI (Solar System Exploration Research Virtual Institute) and is led by Principal Investigator (PI) Dr. Jennifer L. Heldmann and Deputy PIs Dr. Matthew Deans and Dr. Alexander Sehlke at NASA Ames Research Center. RESOURCE is focused on enabling In Situ Resource Utilization (ISRU) near the sites of robotic and/or human missions to enable sustainable and affordable exploration of the Moon and near-Earth objects (NEOs). This year RESOURCE has supported the development of a summary of the current state of knowledge regarding lunar polar volatiles as well as a comprehensive catalog and analysis of NEOs. RESOURCE is developing advanced mission capabilities to enable rapid, collaborative operations for lunar resource exploration missions. Hardware testing has been conducted to evaluate potential contaminants released during lunar polar regolith heating. Volatiles and particulates are the two sources of contamination that will affect the requirements of a water cleanup system, and RESOURCE research has identified the requirement for filtration prior to electrolysis for ISRU. RESOURCE also supports development of next-generation planetary drilling systems with integrated instrumentation within the drill. RESOURCE is also deeply committed to sustained efforts to engage educators, students, and broadening participation among under represented groups, and has partnered with Howard University in Washington, DC to foster minoritized students’ interest in STEAMD (science, technology, engineering, arts, math, design) careers through direct and virtual experiences with NASA Subject Matter Experts.

Jennifer L Heldmann↗
DOE OSTI2026

Spherical tokamak physics research in preparation for the operation of NSTX-U

The National Spherical Torus Experiment Upgrade (NSTX-U) is preparing to resume operation, representing a crucial step toward realizing compact, cost-effective fusion pilot plants. In advance of this, extensive modeling and data analysis have been conducted to advance the physics basis for low-aspect-ratio, high-performance plasma regimes, focusing on three core objectives: confinement and stability, power and particle handling, and steady-state operation. Significant progress has been made in understanding the electron temperature flattening in high-β plasmas, which is shown to be driven by a complex interplay of magnetohydrodynamic instabilities (e.g. non-resonant infernal modes), fast-ion-driven Alfvén eigenmodes, and electron and ion-scale micro-instabilities, particularly Kinetic Ballooning Modes (KBMs), whose destabilization is strongly dependent on parallel magnetic field fluctuations (δB ∥ ). Furthermore, a new gyrokinetic critical pedestal model was developed, accurately predicting pedestal structure by identifying KBMs as the primary stability limit, offering a critical constraint for future high-confinement scenarios. To address the challenge of high heat flux, novel liquid lithium plasma-facing components were modeled. The analysis confirmed that lithium vapor shielding is a self-regulating mechanism for heat mitigation, while also emphasizing that strong main ion parallel flow is essential to minimize core lithium contamination. Finally, progress toward steady-state operation was anchored by developing the required physics basis and control tools. This includes predictive modeling for reversed magnetic shear sustainment, demonstrating that magnetic island-induced bootstrap current reduction is negligible in STs, and advancing real-time control and disruption avoidance capabilities. The development of high-speed surrogate models (e.g. MMMNet) provides computationally efficient tools vital for non-inductive scenario optimization and integrated, low-disruptivity operations planned for NSTX-U.

NSTX-U↗
NASA NTRS1985

Definition of an entry research vehicle

Within the last year, there has been a growing interest in technology which would support the development of vehicles which can maneuver in the atmosphere while returning from orbit and vehicles which can fly in the atmosphere at hypersonic speeds for sustained periods of time. This rebirth of interest in hypersonics is partly a result of a developing awareness of the potential benefits which can be derived from vehicles with capability to operate between the limits of existing aircraft and spacecraft. Examples of the types of maneuvers which are projected for this new class of vehicles are presented. Challenges provided by the considered maneuvers are summarized, taking into account a synergetic or atmospheric plane change. The plane change maneuver will require a Thermal Protection System (TPS). Attention is given to the definition of a Shuttle launched entry research vehicle experiment. Details regarding the synergetic plane change are considered along with the maneuvering entry, vehicle heating, and experiments and instrumentation.

Freeman, D. C.↗
DOE OSTI2022

Editorial: Wood Development and Physiology in a Changing Climate

Wood of forest trees is a renewable, sustainable and easily workable material and has been widely used in construction, paper making, furniture, and as a feedstock for biofuels. Wood formation is the result of a highly ordered and finely regulated process. Secondary xylem (wood) and phloem are the inner and outer derivative products of the vascular cambium, respectively. Xylem is mainly composed of dead cells with thickened cell walls rich in cellulose, hemicelluloses, and lignin, which are responsible for providing mechanical support and conducting water and minerals for the trees. Phloem transports photoassimilates and signaling molecules, including phytohormones and peptides. Wood structure varies greatly between, and within, tree species. A thorough understanding of developmental processes and metabolic pathways during wood formation would provide a basis for improving wood biomass and modifying properties in forest trees.

54 ENVIRONMENTAL SCIENCES↗
NASA NTRS1980

Study of radiatively sustained cesium plasmas for solar energy conversion

The results of a study aimed at developing a high temperature solar electric converter are reported. The converter concept is based on the use of an alkali plasma to serve as both an efficient high temperature collector of solar radiation as well as the working fluid for a high temperature working cycle. The working cycle is a simple magnetohydrodynamic (MHD) Rankine cycle employing a solid electrode Faraday MHD channel. Research milestones include the construction of a theoretical model for coupling sunlight in a cesium plasma and the experimental demonstration of cesium plasma heating with a solar simulator in excellent agreement with the theory. Analysis of a solar MHD working cycle in which excimer laser power rather than electric power is extracted is also presented. The analysis predicts a positive gain coefficient on the cesium-xenon excimer laser transition.

Palmer, A. J.↗
NASA NTRS2017

System-of-Systems Considerations in the Notional Development of a Metropolitan Aerial Transportation System

There are substantial future challenges related to sustaining and improving efficient, cost-effective, and environmentally friendly transportation options for urban regions. Over the past several decades there has been a worldwide trend towards increasing urbanization of society. Accompanying this urbanization are increasing surface transportation infrastructure costs and, despite public infrastructure investments, increasing surface transportation "gridlock." In addition to this global urbanization trend, there has been a substantial increase in concern regarding energy sustainability, fossil fuel emissions, and the potential implications of global climate change. A recently completed study investigated the feasibility of an aviation solution for future urban transportation (refs. 1, 2). Such an aerial transportation system could ideally address some of the above noted concerns related to urbanization, transportation gridlock, and fossil fuel emissions (ref. 3). A metro/regional aerial transportation system could also provide enhanced transportation flexibility to accommodate extraordinary events such as surface (rail/road) transportation network disruptions and emergency/disaster relief responses.

Alonso, Juan J.↗
NASA NTRS2019

NASA’s In-Space Manufacturing Project: Update on Manufacturing Technologies and Materials to Enable More Sustainable and Safer Exploration

NASA’s In-Space Manufacturing (ISM) project seeks to develop the materials, processes, and manufacturing technologies needed to provide an on-demand manufacturing capability for deep space exploration missions. The ability to manufacture and recycle some parts on demand rather than launch them from earth has the potential to reduce logistics requirements on long duration missions and enhance crew safety. With the launch of the first 3D printer (built and operated by Made in Space through a Small Business Innovative Research – SBIR -- contract) to the International Space Station (ISS) in 2014, the ISM project demonstrated the feasibility of operating an on-demand manufacturing system in a microgravity environment. This paper will provide an update on recent advancements in ISM under three key technology areas: manufacturing, recycling, and development of a design database. ISM continues to pursue development of manufacturing technologies for space applications and use the ISS as a critical test bed to prove out these technologies before deploying them on next generation exploration systems. Activities under this focus area include: characterization of materials manufactured using the Additive Manufacturing Facility (AMF), the second generation commercial 3D-printer on ISS, also owned and operated by Made in Space; development of prototype payloads for metal manufacturing through phase II SBIR contracts with Tethers Unlimited, Made in Space, and Ultra Tech Machinery; development of a multi-material fabrication laboratory capable of processing metals and providing inspection of manufactured parts through a Broad Agency Announcement (Techshot, Interlog, and Tethers Unlimited); an in-line sensing system for ISM platforms; and development of higher strength feedstocks for 3D polymer printers. In the area of recycling, the Tethers Unlimited Refabricator payload (an integrated 3D printer and recycler for ULTEM 9085) launched to ISS in November 2018 and began operating in early 2019. This payload represents the first demonstration of on-orbit recycling; down massed specimens will assess material degradation in the polymer over multiple recycling cycles to define limits on material re-use. Other work in the recycling area includes development of common use materials intended to be reused and recycled on space missions (Tethers Unlimited and Cornerstone Research Group) and a sterilization capability for multiple-use materials (ERASMUS from Tethers Unlimited). Concurrent with manufacturing technology and materials development work is creation of a design database, a curated list of parts that can be manufactured using the suite of In-Space Manufacturing capabilities.

Tracie Prater↗
NASA NTRS2018

Building a Plastics Fabrication Laboratory on the ISS: FabLab, MANTIS, Refabricator, CRISSP, ERASMUS, and MAMBA

The objective of NASA's In Space Manufacturing program is to develop manufacturing technologies and processes necessary to provide "on-demand, sustainable operations for exploration missions." Using the ISS as a test bed, in 2014, NASA installed and successfully tested a 3D printer for in-space operations, demonstrating the 3D printing process as well as sending digital files for printing from earth to the printer. The success of this technology demonstration has shown that on-orbit manufacturing technologies can be used to limit the earth reliance for cis-lunar missions. Because of this success, numerous opportunities have been provided by NASA to further in-space manufacturing by focusing on the development of highly autonomous manufacturing systems, recycling technologies, and robotics with the ultimate goal of building a fabrication laboratory now within reach. From technologies developed for ISS activities and demonstration missions, Tethers Unlimited, Inc. (TUI) is building a Plastics Manufacturing Laboratory capable of fabricating parts on-demand and as-needed while recycling waste plastics with minimal human interaction required. Parts will be manufactured through additive manufacturing. Precision machining will ensure manufactured parts are in tolerance with the end-use requirements. Recycling waste plastics will enable both waste from the crew and waste from processing to be re-processed into something new. In addition, these manufacturing and recycling technologies are supported by part verification/validation technique and robotic servicing, minimizing human interaction with the system and eventually enabling unmanned off-world manufacturing.

Muhlbauer, Rachel↗