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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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All sources NASA NTRS DOE OSTI

DOE OSTI2025

Soft costs and EVSE – Knowledge gaps as a barrier to successful projects

There has been a recent push to increase access to electric vehicle (EV) charging infrastructure. The National Electric Vehicle Infrastructure (NEVI) program, part of the Bipartisan Infrastructure Law (BIL) has made significant funding available for major charging infrastructure projects along state thruways, and many state and local incentives exist for EV owners to install chargers in their homes. However, deployment of these chargers has not kept up with demand, primarily due to issues in project planning, permitting processes, and unforeseen delays. This paper serves as a review of the current understanding of these and other non-hardware costs in EV charging infrastructure projects (collectively known as “soft costs”). We found that soft costs in EV charging infrastructure projects are not well understood. Specifically, there is little agreement on how soft costs should be categorized and tracked, and less agreement still on best practices for controlling these costs and lowering barriers to infrastructure deployment. A broader review of EV charging infrastructure cost analyses shows that these costs can have significant impacts on project outcomes. EV charging infrastructure projects may be able to examine the success of the solar industry in lowering soft costs, and a similar effort may lower project costs significantly. Further work on standardizing and collecting data on EV charging infrastructure costs is required to begin addressing and controlling these costs.

32 - ENERGY CONSERVATION, CONSUMPTION, AND UTILIZA↗

DOE OSTI2024

EVSE Soft Costs

This presentation is an overview of the VTO Annual Merit Review for EVSE soft costs project.

ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2025

Smart Meter Data: A Gateway for Reducing Solar Soft Costs with Model-Free Hosting Capacity Maps

Public-facing solar hosting capacity (HC) maps, which show the maximum amount of solar energy that can be installed at a location without adverse effects, have proven to be a key driver of solar soft cost reductions through a variety of pathways (e.g., streamlining interconnection, siting, and customer acquisition processes). However, current methods for generating HC maps require detailed grid models and time-consuming simulations that limit both their accuracy and scalability—today, only a handful out of almost 2,000 utilities provide these maps. This project developed and validated data-driven algorithms for calculating solar HC using data from AMI without the need of detailed grid models or simulations. The algorithms were validated on utility datasets and incorporated as an application into NRECA’s Open Modeling Framework (OMF.coop) for the over 260 coops and vendors throughout the US to use. The OMF is free and open-source for everyone.

14 SOLAR ENERGY↗

DOE OSTI2026

A Simple Panel System to Overcome Interface Challenges for Retrofits: Preprint

Retrofitting buildings is usually an expensive and labor-intensive process. Weatherization measures can improve comfort and energy affordability to some extent, but deep energy retrofits are needed to optimize performance and comfort, and to achieve significant energy cost savings. Barriers to deep energy retrofits include a limited supply of skilled labor, different building types, planning complexity, split incentives, and a long or non-existent ROI horizon. The "Simple Panel System" (SPS) workflow developed and demonstrated in this effort streamlines deep energy retrofits by applying advanced site capture, machine learning, and mixed reality to panelized construction. The result is a one-stop, product-independent solution for rapidly scalable retrofits with the potential to reduce construction time and project costs by 50%. Soft costs are reduced by more than 66%, total costs by more than 50%, and field construction time by more than 50% - not to mention the reduction in construction waste, improvement in working conditions, and the ability to scale without an influx of skilled labor. This paper presents the SPS and the preliminary results and findings from the pilot project.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2025

Q1-2024 Solar Cost Benchmarks

Each year, the U.S. Department of Energy’s (DOE) Solar Energy Technologies Office (SETO) and its national laboratory partners develop cost benchmarks for U.S. solar photovoltaic (PV) systems. These benchmarks track progress toward reducing solar costs and guide R&D priorities. Unlike typical studies that report only $/W, SETO uses intrinsic units (e.g., $/m² for mounting structures) to better capture how technology improvements such as module efficiency would impact system costs. This allows flexible modeling where inputs can vary significantly to assess cost sensitivity. Costs are reported in two ways: Minimum Sustainable Price (MSP): Long term, financially viable price under stable market conditions. Modeled Market Price (MMP): Actual market price, influenced by short term distortions such as tariffs or subsidies. Three national labs collect cost data from industry stakeholders, ensuring no duplication in outreach to stakeholders. Data reflects real transactions (primarily from Q1) and is weighted based on the number of sources per cost element. The PV System Cost Model (PVSCM) divides total installed system cost into eight categories: 1. Module (PV) 2. Inverter 3. Energy Storage System (ESS) 4. Structural BOS (SBOS) 5. Electrical BOS (EBOS) 6. Fieldwork 7. Office work 8. Other (developer/EPC costs) The first five are hardware costs, while the last three are soft costs. Each category includes fixed and variable cost components, where “size” depends on context (e.g., manufacturing capacity for modules vs. system capacity for installation costs). Variable costs are expressed using appropriate intrinsic units. The model reflects the owner’s upfront overnight capital cost, excluding tax credits. Tariffs and subsidies are treated as temporary market distortions affecting MMP but not MSP. PVSCM is implemented in Excel, where cost elements are aggregated into total system cost. Additional sheets handle unit conversions and operation & maintenance (O&M), with O&M costs levelized over the system’s lifetime.

14 SOLAR ENERGY↗

DOE OSTI2026

An AI-driven framework for evaluating local and state authorities’ permitting processes

The demand for new energy infrastructure is increasing across the United States, but heterogenous permitting processes and embedded requirements across different local jurisdictions can cause project delays, increase “soft costs,” and hinder developer expansion. This study analyzes the variability in local permitting requirements across the U.S. and develops a quantitative approach to describe their clarity and effectiveness in enabling infrastructure project development. By using an Energy Language Model (ELM), a large language model (LLM) for energy technologies, we systematically gathered permitting information from nearly 300 state-, county-, and city-level documents, creating a structured dataset of requirements and procedures on an unprecedented scale and speed. Our analysis revealed that local (city and county) permitting requirement documents are underrepresented compared to state-level guidance documents, which can impede timely and cost-effective installation of new electric infrastructure. Our validation process showed that the final database has an accuracy of approximately 95%. We, further, created a new quantitative method to score permitting requirements for clarity and efficiency, with electric vehicle supply equipment as an initial use case. The average local permitting document scored a 1.8 out of 5, which we interpret as meaning that half of the requirements developers face when installing electric infrastructure are ambiguous, increasing both cost and time. We also created a “Generalized Permit Process”, highlighting common procedural steps and identifying specific opportunities for municipalities to improve their documentation. This research establishes a systematic and scalable framework for evaluating the complexities of local infrastructure permitting processes by combining LLM-powered data collection and quantitative scoring. The framework enables policymakers and developers to identify and mitigate procedural bottlenecks, with the expectation that these improvements can accelerate application review and approval, reduce project costs, and expedite connection to utility distribution grids. As a foundational approach for streamlining local project development processes, this study’s methods are intended to be extended to a wide range of energy applications.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2025

Documenting 15 Years of Reductions in U.S. Solar Photovoltaic System Costs

The U.S. Department of Energy's (DOE) Solar Energy Technologies Office (SETO) has played a key role in reducing PV system costs by supporting essential and high-impact research, development, and deployment (RD&D) activities. SETO's efforts go beyond improving technology and hardware innovations to tackle soft costs like installation labor, permitting, and customer acquisition. This holistic focus ensures that solar energy remains a viable, scalable solution for combating climate change and achieving the nation's clean energy goals. This National Renewable Energy Laboratory's (NREL) report highlights over a decade of transformative advancements in PV system technology and its cost reductions from 2010 to 2024, documenting a remarkable trajectory in line with the goals set forth by SETO. By analyzing benchmark configurations across different photovoltaic (PV) sectors over years, this work provides industry stakeholders with a comprehensive understanding of cost trends and their impact on Levelized Cost of Energy (LCOE) targets established under the 2010 SunShot Initiative.

14 SOLAR ENERGY↗

DOE OSTI2025

Solar@Scale: Improving the Local Rules of the Game for Large Scale Solar

This final report summarizes the Solar@Scale Project including project goals, milestones, tasks and deliverables. Solar@Scale, led by ICMA in partnership with the American Planning Association, took place from 2020-2025. The initiative addressed large-scale solar soft costs by developing tools and resources related to planning, siting, permitting and inspection in support of local governments, special districts, and other authorities that have jurisdiction over large-scale solar projects.

14 SOLAR ENERGY↗

DOE OSTI2026

Solar and Battery Storage Permitting and Siting Requirements - Solar Prize Round 7 (CRADA Final Report)

The purpose of this research project was to aggregate zoning and permitting data for utility-scale solar PV and battery energy storage systems. The ultimate goal of this collaboration is to lower solar and battery energy storage system soft costs by streamlining regulatory due diligence and reducing the burden of conducting feasibility assessments for solar and storage systems. The below sections describe the specific research completed by NLR (the contractor) in furtherance of the agreement with Vanox (the participant).

14 SOLAR ENERGY↗

NASA NTRS2022

Scheduling For Urban Air Mobility Using Safe Learning

This work considers the scheduling problem for Urban Air Mobility (UAM) vehicles travelling between origin-destination pairs with both hard and soft trip deadlines. Each route is described by a discrete probability distribution over trip completion times (or delay) and over interarrival times of requests (or demand) for the route along with a fixed hard or soft deadline. Soft deadlines carry a cost that is incurred when the deadline is missed. An online, safe scheduler is developed that ensures that hard deadlines are never missed and that average cost of missing soft deadlines is minimized. The system is modelled as a Markov Decision Process (MDP) and safe model based learning is used to find the probabilistic distributions over route delays and demand. Monte Carlo Tree Search (MCTS) Earliest Deadline First (EDF) is used to safely explore the learned models in an online fashion and develop a near-optimal non-preemptive scheduling policy. These results are compared with Value Iteration (VI) and MCTS (Random) scheduling solutions.

Urban Air Mobility↗

NASA NTRSDate not supplied

Scheduling for Urban Air Mobility using Safe Learning

Urban Air Mobility↗

DOE OSTI2026

Stations Tool for Automated Permitting (S-TAP) User Manual

The Stations Tool for Automated Permitting (S-TAP) is a spreadsheet-based plan review questionnaire designed to help automate and expedite the electric vehicle supply equipment (EVSE) permitting process. This manual goes into detail on the development of the tool and guidance for use cases of the tool.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

NASA NTRS1991

High resolution imaging with multilayer soft X-ray, EUV and FUV telescopes of modest aperture and cost

The development of multilayer reflective coatings now permits soft X-ray, EUV and FUV radiation to be efficiently imaged by conventional normal incidence optical configurations. Telescopes with quite modest apertures can, in principle, achieve images with resolutions which would require apertures of 1.25 meters or more at visible wavelengths. The progress is reviewed which has been made in developing compact telescopes for ultra-high resolution imaging of the sun at soft X-ray, EUV and FUV wavelengths, including laboratory test results and astronomical images obtained with rocket-borne multilayer telescopes. The factors are discussed which limit the resolution which has been achieved so far, and the problems which must be addressed to attain, and surpass the 0.1 arc-second level. The application of these technologies to the development of solar telescopes for future space missions is also described.

Walker, Arthur B. C., Jr.↗

NASA NTRS2011

Safe, Advanced, Adaptable Isolation System Eliminates the Need for Critical Lifts

The Starr Soft Support isolation system incorporates an automatically reconfigurable aircraft jack into NASA's existing 1-Hertz isolators. This enables an aircraft to float in mid-air without the need for a critical lift during ground vibration testing (GVT), significantly reducing testing risk, time, and costs. Currently incorporating the most advanced technology available, the 60,000-poundcapacity (27-metric-ton) isolation system is used for weight and measurement tests, control-surface free-play tests, and structural mode interaction tests without the need for any major reconfiguration, often saving days of time and significantly reducing labor costs. The Starr Soft Support isolation system consists of an aircraft-jacking device with three jacking points, each of which has an individual motor and accommodates up to 20,000 pounds (9 metric tons) for a total 60,000-pound (27-metric-ton) capacity. The system can be transported to the aircraft by forklift and placed at its jacking points using a pallet jack. The motors power the electric actuators, raising the aircraft above the ground until the landing gear can retract. Inflatable isolators then deploy, enabling the aircraft to float in mid-air, simulating a 1-Hertz free-free boundary condition. Inflatable isolators have been in use at NASA for years, enabling aircraft to literally float unsupported for highly accurate GVT. These isolators must be placed underneath the aircraft for this to occur. Traditionally, this is achieved by a critical lift a high-risk procedure in which a crane and flexible cord system are used to lift the aircraft. In contrast, the Starr Soft Support isolation system eliminates the need for critical lift by integrating the inflatable isolators into an aircraft jacking system. The system maintains vertical and horizontal isolating capabilities. The aircraft can be rolled onto the system, jacked up, and then the isolators can be inflated and positioned without any personnel needing to work underneath the aircraft. Also, the system accommodates changes in aircraft configuration, automatically adapting to changes in mass, and it can adjust the height of the isolators in one basic setup. Dryden personnel used the Starr Soft Support system to successfully perform a GVT on an F-15 being structurally modified by Gulfstream, Dryden's Gulfstream III used for science research and the crew exploration module and adaptor cone assembly.

Ginn, Starr↗

DOE OSTI2025

Additive manufacturing of amorphous metal soft magnetic composites

Soft magnet alloys are used as magnetic cores for electric motors, transformers, wind turbines and other power generation systems. Soft magnetic cores are expensive and time consuming to manufacture in the complex shapes required for next-generation devices using conventional press and sinter powder metallurgy. The objective of this effort is to additively manufacture high performance soft magnets, with reduced cost and reduced material waste and 10x lower energy (core) loss at the high operating frequencies of many electric machines. Laser powder bed fusion additive manufacturing is used as the fabrication method. Electrical steel and amorphous alloys atomized powders are used as a feedstock materials. Magnetic cores are printed in topology optimized structures such as the Hilbert curve because this has been shown to reduce energy losses by minimizing the eddy currents that circulate within the magnet at high frequencies. In our project, we succeed in printing FeSi 3.5wt% and FeSi 6.5wt% electrical steels, and iron-based soft magnetic amorphous alloys in the shape of Hilbert and Peano curve topology optimized structures. We found that the Peano curve has a higher cut-off frequency than the Hilbert curve, and that amorphous alloys have high cut-off frequencies and higher mechanical hardness than electrical steels. Processing conditions such as laser power, scan speed, and hatching pattern were optimized to achieve high density prints, and optimize magnetic performance. We find that the printing of amorphous alloy soft magnetic cores may be technoeconomically feasible for large scale applications such as transformers, for which supply chain issues and the labor costs of manual fabrication of magnetic cores is prohibitive in some cases.

36 MATERIALS SCIENCE↗

NASA NTRS2014

NASA HUNCH Hardware

What is NASA HUNCH? High School Students United with NASA to Create Hardware-HUNCH is an instructional partnership between NASA and educational institutions. This partnership benefits both NASA and students. NASA receives cost-effective hardware and soft goods, while students receive real-world hands-on experiences. The 2014-2015 was the 12th year of the HUNCH Program. NASA Glenn Research Center joined the program that already included the NASA Johnson Space Flight Center, Marshall Space Flight Center, Langley Research Center and Goddard Space Flight Center. The program included 76 schools in 24 states and NASA Glenn worked with the following five schools in the HUNCH Build to Print Hardware Program: Medina Career Center, Medina, OH; Cattaraugus Allegheny-BOCES, Olean, NY; Orleans Niagara-BOCES, Medina, NY; Apollo Career Center, Lima, OH; Romeo Engineering and Tech Center, Washington, MI. The schools built various parts of an International Space Station (ISS) middeck stowage locker and learned about manufacturing process and how best to build these components to NASA specifications. For the 2015-2016 school year the schools will be part of a larger group of schools building flight hardware consisting of 20 ISS middeck stowage lockers for the ISS Program. The HUNCH Program consists of: Build to Print Hardware; Build to Print Soft Goods; Design and Prototyping; Culinary Challenge; Implementation: Web Page and Video Production.

manufacturing↗

NASA NTRSDate not supplied

Differential Dynamic Microscopy: A Novel Approach for Dynamics and Micro-rheology of Active Soft Matter

Differential dynamic microscopy (DDM) is a highly sensitive and cost-effective technique for studying the dynamics and micro-rheology of active soft matter in real time and at high resolution. In this work, we extend the capabilities of DDM, notably its size, to suit to space research and overcome challenges such as the environmental limited resources (e.g. Artemis, ISS, Cube sat, etc.).

Amine Missaoui↗

NASA NTRS1984

Generating soft shadows with a depth buffer algorithm

Computer-synthesized shadows used to appear with a sharp edge when cast onto a surface. At present the production of more realistic, soft shadows is considered. However, significant costs arise in connection with such a representation. The current investigation is concerned with a pragmatic approach, which combines an existing shadowing method with a popular visible surface rendering technique, called a 'depth buffer', to generate soft shadows resulting from light sources of finite extent. The considered method represents an extension of Crow's (1977) shadow volume algorithm.

Brotman, L. S.↗