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DOE OSTI2026

Future foundries: A convergent manufacturing platform

This article introduces the Future Foundries platform developed at Oak Ridge National Laboratory, a first-generation research system designed to demonstrate convergent manufacturing. Convergent manufacturing brings together additive, subtractive, and transformative processes in a digitally interconnected environment to enable end-to-end production workflows. By linking traditionally discrete steps, convergent platforms accelerate production, improve repeatability, and support high-mix, low-volume manufacturing. The Future Foundries platform exemplifies this vision in practice by combining four modular, vendor-agnostic process cells that include robotic WAAM, induction heating, optical metrology, and machining, coordinated through an automated pallet handler and a ROS 2-based digital thread. This architecture provides the flexibility and scalability needed for agile production in small and medium-sized manufacturing enterprises and for field deployable manufacturing. Two case studies illustrate the platform’s capabilities. The first presents an integrated workflow for fabricating, transforming, and repairing critical replacement components, showing how consolidated thermal, additive, inspection, and machining operations reduce manual part handling and streamline process flow. The second case study highlights coordinated multi-part production enabled by automated pallet logistics and multi-cell scheduling. Together, these examples showcase convergent manufacturing as a practical and scalable strategy for strengthening domestic casting and forging capacity, improving supply-chain resilience, and enabling rapid, adaptable production of mission-critical components.

Convergent manufacturing↗

NASA NTRS1978

An adaptive learning control system for aircraft

A learning control system and its utilization as a flight control system for F-8 Digital Fly-By-Wire (DFBW) research aircraft is studied. The system has the ability to adjust a gain schedule to account for changing plant characteristics and to improve its performance and the plant's performance in the course of its own operation. Three subsystems are detailed: (1) the information acquisition subsystem which identifies the plant's parameters at a given operating condition; (2) the learning algorithm subsystem which relates the identified parameters to predetermined analytical expressions describing the behavior of the parameters over a range of operating conditions; and (3) the memory and control process subsystem which consists of the collection of updated coefficients (memory) and the derived control laws. Simulation experiments indicate that the learning control system is effective in compensating for parameter variations caused by changes in flight conditions.

Mekel, R.↗

NASA NTRS1988

A parallel row-based algorithm with error control for standard-cell replacement on a hypercube multiprocessor

A new row-based parallel algorithm for standard-cell placement targeted for execution on a hypercube multiprocessor is presented. Key features of this implementation include a dynamic simulated-annealing schedule, row-partitioning of the VLSI chip image, and two novel new approaches to controlling error in parallel cell-placement algorithms; Heuristic Cell-Coloring and Adaptive (Parallel Move) Sequence Control. Heuristic Cell-Coloring identifies sets of noninteracting cells that can be moved repeatedly, and in parallel, with no buildup of error in the placement cost. Adaptive Sequence Control allows multiple parallel cell moves to take place between global cell-position updates. This feedback mechanism is based on an error bound derived analytically from the traditional annealing move-acceptance profile. Placement results are presented for real industry circuits and the performance is summarized of an implementation on the Intel iPSC/2 Hypercube. The runtime of this algorithm is 5 to 16 times faster than a previous program developed for the Hypercube, while producing equivalent quality placement. An integrated place and route program for the Intel iPSC/2 Hypercube is currently being developed.

Sargent, Jeff Scott↗

NASA NTRS1989

A parallel row-based algorithm for standard cell placement with integrated error control

Sargent, Jeff S.↗

NASA NTRS2007

Orion-CEV Project Overview To the NASA Sports and Exploration "Kick-Off" Meeting

This viewgraph presentation reviews the Orion Crew Exploration vehicle (CEV) and its usage in the exploration of the moon and subsequent travel to Mars. Schedules for development and testing of the CEV are shown. Also displayed are various high level design views of the CEV, the launch abort system, the Atlas Docking adapter, and the service module.

Marshall, Paul F.↗

NASA NTRS2008

FPGA Control System for the Automated Test of Microshutters

The James Webb Space Telescope, scheduled to replace the Hubble in 2013, must simultaneously observe hundreds of faint galaxies. This requirement has led to the development of a programmable transmission mask which can be adapted to admit light with arbitrary pattern of galaxies into its spectrograph. This programmable mask will contain a large array of micro-electromechanical (MEMs) devices called MicroShutters. These microscopic shutters physically open and close like the shutter on a camera, except each shutter is microscopic in size and an array 365 by 171 is used to select the objects under spectroscopic observation at a given time, and to block the unwanted background light from other areas. NASA developed and is currently refining the exceptionally difficult process of manufacturing these shutters. This paper describes how the authors used LabVIEW FPGA and a reconfigurable I/O board to control the shutters in a test chamber and how the flexibility of the system allows us to continue to modify the control algorithms as NASA optimizes the performance of the MicroShutter arrays.

Lyness, Eric↗

NASA NTRS2008

FPGA Control System for the Automated Test of MicroShutters

The James Webb Space Telescope, scheduled to replace the Hubble in 2013, must simultaneously observe hundreds of faint galaxies. This requirement has led to the development of a programmable transmission mask which can be adapted to admit light from an arbitrary pattern of galaxies into its spectrograph. This programmable mask will contain a large array of micro-electromechanical (MEMs) devices called MicroShutters. These microscopic shutters physically open and close like the shutter on a camera, except each shutter is microscopic in size and an array 365 by 171 is used to select the objects under spectroscopic observation at a given time, and to block the unwanted background light from other areas. NASA developed and is currently refining the exceptionally difficult process of manufacturing these shutters. This paper describes how the authors used LabVIEW FPGA and a reconfigurable I/O board to control the shutters in a test chamber and how the flexibility of the system allows us to continue to modify the control algorithms as NASA optimizes the performance of the MicroShutter arrays.

Lyness, Eric↗

NASA NTRS2016

On-orbit RNA Purification and qRT-PCR Capabilities of the WetLab-2 System

NASA Ames Research Center’s WetLab-2 system brings new capabilities to the ISS for researchers. The system can lyse cells and extract RNA on-orbit from different sample types ranging from microbial cultures to animal tissues. Our purification method has the advantage of using non-toxic chemicals and does not require alcohols or other organics. The purified RNA can then either be stabilized for return to Earth or can be used to conduct on-orbit quantitative Reverse Transcriptase PCR (qRT-PCR) analysis without the need for sample return. qRT-PCR reactions are performed by dispensing the RNA into reaction tubes that contain all lyophilized reagents needed to perform the analysis. The system uses a Cepheid® SmartCycler that allows for multiplexing of assays, this can be used to normalize for RNA concentration and integrity and to study multiple genes of interest in each tube. There are a total of 16 independent PCR modules each capable of detecting up to four fluorescent channels. The WetLab- 2 system can downlink data from the ISS to the ground after a completed run and uplink new thermal cycling programs. The ability to purify and stabilize RNA on-orbit can eliminate the confounding effects of reentry stresses and shock acting on live cells and organisms or the concern of RNA degradation of some samples. It also has the benefit of minimizing the needed downmass. Conducting qRT-PCR and generating results on-orbit is also an important step towards utilizing the ISS as a National Laboratory facility. Specifically, the ability to get on-orbit data will provide investigators with the opportunity to adjust experimental parameters in real time without the need for sample return and re-flight. On orbit gene expression analysis can also provide benchmarking prior to sample return. The system can also be used for analysis of air, surface, water, and clinical samples to monitor environmental pathogens and crew health. The validation flight of the WetLab-2 system using E. coli bacteria and mouse liver is scheduled to launch on SpaceX-8 this spring. Pending operations, the preliminary results from the validation flight will be presented. To support the needs of future researchers, we are adapting our system to purify RNA from two additional sample types: fibrous tissue such as muscle and mammalian adherent cells grown on alginate beads. Progress of this work will also be presented. The WetLab-2 Project is supported by the Research Integration Office in the ISS Program.

Parra, Macarena↗

NASA NTRS2021

Towards the Development of a Multi-Agent Cognitive Networking System for the Lunar Environment

This paper details the development of a multi-agent cognitive system intended to optimize networking performance in the lunar environment. NASA’s current concept of the future of lunar communication, LunaNet [1], outlines a complex network of networks. Challenges such as scalability, interoperability and reliability must first be addressed to successfully fulfill this vision. Machine intelligence can greatly reduce the reliance on human operators and enable efficient operations for tasks such as scheduling and network management. The application of machine learning, artificial intelligence, and other automated decision-making techniques can be used to allow network nodes to intelligently sense and adapt to changes in the environment such as link disruptions, new nodes joining the network, and support for a diverse range of protocols. Cognitive networking seeks to evolve these technologies into an autonomous system with improved science data return, reliability, and scalability. In this paper, we study three main areas a means to further develop cognitive networking capabilities: networking and flight software development, analysis of wireless data for modeling and simulation, and development of algorithms for a multi-agent system.

Cognitive Networking↗

NASA NTRSDate not supplied

Towards the Development of a Multi-Agent Cognitive Networking System for the Lunar Environment

This paper details the development of a multi-agent cognitive system intended to optimize networking performance in the lunar environment. NASA’s current concept of the future of lunar communication, LunaNet, outlines a complex network of networks. Challenges such as scalability, interoperability and reliability must first be addressed to successfully fulfill this vision. Machine intelligence can greatly reduce the reliance on human operators and enable efficient operations for tasks such as scheduling and network management. The application of machine learning, artificial intelligence, and other automated decision-making techniques can be used to allow network nodes to intelligently sense and adapt to changes in the environment such as link disruptions, new nodes joining the network, and support for a diverse range of protocols. Cognitive networking seeks to evolve these technologies into an autonomous system with improved science data return, reliability, and scalability. In this paper, we study three main areas a means to further develop cognitive networking capabilities: networking and flight software development, analysis of wireless data for modeling and simulation, and development of algorithms for a multi-agent system.

Rachel Dudukovich↗

NASA NTRSDate not supplied

Development of a Safety Hazards Risk Assessment Tool for Uncrewed Aircraft System Traffic Management during Preflight Planning

Tremendous growth in the uncrewed and remotely piloted vehicle market is expected in low-altitude, uncontrolled airspace, resulting in potential decreases in safety without systems that support monitoring, assessing, and mitigating risk. At NASA, the System-Wide Safety (SWS) project has been developing a suite of data-driven tools to predict hazards so that the potential risks that these hazards pose can be mitigated. Services to predict various hazards have been developed, including battery capacity, proximity to static obstacles, population risks, global positioning system signal strength, radio frequency spectrum interference risk, and vertiport congestion. These services can monitor hazards along a flight path and if any risks posed by these hazards exceed a threshold, the uncrewed aircraft system (UAS) fleet manager can be alerted to mitigate the risk by modifying the flight path, changing the scheduled departure or arrival times, and/or diverting the vehicle to an alternate vertiport. These services were originally developed to monitor and assess risks during flight, but they have been adapted to assess hazard risks prior to departure so that a fleet manager can evaluate the potential risks for a fleet of UAS along their planned flight paths. These services have been integrated into a prototype tool called the Supplemental Data Service Provider-Consolidated Dashboard (SDSP-CD), developed at NASA Ames Research Center. The tool consists of a dashboard which provides a comprehensive overview for a number of risks and a map display that shows the details of the hazards along each flight’s path. Based on the findings from three previous studies, the SDSP-CD has been updated with new design elements and functions. In this paper, we describe lessons learned from the previous studies, changes made to the interface, and the feedback received during a follow-up usability study. Overall, participants reported that there is a substantial benefit of having a fleet manager use a consolidated dashboard to assess hazards for the vehicles in their fleet and to provide situational awareness to potential risks so that they can be mitigated prior to flight. Once the SDSP-CD matures, it will need to be integrated into flight and mission planning tools. Some initial thoughts on how this integration should be accomplished are shared in this paper. Finally, the functional differences between preflight vs. in-flight risk assessment and the differences in fleet manager vs. UAS pilot roles that may require different information and user interactions are discussed.

preflight↗

NASA NTRS1998

Progressive content-based retrieval of image and video with adaptive and iterative refinement

A method and apparatus for minimizing the time required to obtain results for a content based query in a data base. More specifically, with this invention, the data base is partitioned into a plurality of groups. Then, a schedule or sequence of groups is assigned to each of the operations of the query, where the schedule represents the order in which an operation of the query will be applied to the groups in the schedule. Each schedule is arranged so that each application of the operation operates on the group which will yield intermediate results that are closest to final results.

Li, Chung-Sheng↗

NASA NTRS1986

Application of parameter estimation to aircraft stability and control: The output-error approach

The practical application of parameter estimation methodology to the problem of estimating aircraft stability and control derivatives from flight test data is examined. The primary purpose of the document is to present a comprehensive and unified picture of the entire parameter estimation process and its integration into a flight test program. The document concentrates on the output-error method to provide a focus for detailed examination and to allow us to give specific examples of situations that have arisen. The document first derives the aircraft equations of motion in a form suitable for application to estimation of stability and control derivatives. It then discusses the issues that arise in adapting the equations to the limitations of analysis programs, using a specific program for an example. The roles and issues relating to mass distribution data, preflight predictions, maneuver design, flight scheduling, instrumentation sensors, data acquisition systems, and data processing are then addressed. Finally, the document discusses evaluation and the use of the analysis results.

Maine, Richard E.↗

NASA NTRS2021

ORCAS – Orbiting Configurable Artificial Star Mission Architecture

In this paper, we establish the mission operation concept for the Orbiting Configurable Artificial Star mission, a hybrid space-ground observatory, which aims to enable ground observations of near-diffraction limited resolution and exquisite sensitivity. We present the mission requirements, introduce a potential orbit solution that can meet them, detail the concrete operational steps to be taken to enable such observations, and develop a mission planning tool which generates a mission schedule that meets all mission requirements and can be altered in real time in the case of disruptions to the mission. Finally, we show the the mission could enable 300 adaptive optics and 1500 flux calibration observations throughout its lifetime.

Eliad Peretz↗

NASA NTRS1992

CABINS: Case-based interactive scheduler

In this paper we discuss the need for interactive factory schedule repair and improvement, and we identify case-based reasoning (CBR) as an appropriate methodology. Case-based reasoning is the problem solving paradigm that relies on a memory for past problem solving experiences (cases) to guide current problem solving. Cases similar to the current case are retrieved from the case memory, and similarities and differences of the current case to past cases are identified. Then a best case is selected, and its repair plan is adapted to fit the current problem description. If a repair solution fails, an explanation for the failure is stored along with the case in memory, so that the user can avoid repeating similar failures in the future. So far we have identified a number of repair strategies and tactics for factory scheduling and have implemented a part of our approach in a prototype system, called CABINS. As a future work, we are going to scale up CABINS to evaluate its usefulness in a real manufacturing environment.

Miyashita, Kazuo↗

NASA NTRS1978

Coaxial isolator has versatile interface

Approach increases system-packaging flexibility. Isolators are constructed with removable connectors that can be changed to meet user's requirements. Technique reduces development scheduling problems. Isolators can be procured before package design is firm and then readily reconfigured to meet final design requirements. Changes to existing designs to incorporate removable connectors are minimal. Small adapter plates increase size modestly; weight increase is negligible.

Olsson, D. L.↗

NASA NTRS2006

A Countermeasure for Space Motion Sickness

Overall, the results obtained in both the U.S. and the Russian space programs indicate that most space crews will experience some symptoms of motion sickness (MS) causing significant impact on the operational objectives that must be accomplished to assure mission success. At this time the primary countermeasure for MS requires the administration of Promethazine. Promethazine is not a benign drug, and is most frequently administered just prior to the sleep cycle to prevent its side effects from further compromising mission objectives. Clearly other countermeasures for SMS must be developed. Currently the primary focus is on two different technologies: (1) developing new and different pharmacological compounds with less significant side effects, (2) preflight training. The primary problem with all of these methods for controlling MS is time. New drugs that may be beneficial are years from testing and development, and preflight training requires a significant investment of crew time during an already intensive pre-launch schedule. Granted, motion sickness symptoms can be minimized with either of the two methods detailed above, however, it may be possible to develop a countermeasure that does not require either extensive adaptation time or exposure to motion sickness. Approximately 25 years ago Professor Geoffrey Melvill Jones presented his work on adaptation of the vestibuloocular reflex (VOR) using optically reversed vision (left-right prisms) during head rotations in the horizontal plane. It was of no surprise that most subjects experienced motion sickness while wearing the optically reversing prisms. However, a serendipitous finding emerged during this research showing that the same subjects did not experience motion sickness symptoms when wearing the reversing prisms under stroboscopic illumination. The mechanism, by which this side-effect was believed to have occurred, is not clearly understood. However, the fact that no motion sickness was ever noted, suggests the possibility of producing functionally useful adaptation during space flight without the penalty of disabling motion sickness by controlling the rate of the adaptive process by means of an appropriate stroboscopically presented environment. After several recent meetings with Professor Melvill Jones, we were encouraged to repeat the motion sickness portions of his and Mandl's 1981 stroboscopic experiment. In conducting this experiment we used a randomized cross-over design where subjects were randomly assigned to either a stroboscopic flash or no strobe for their first exposure in the experimental design. Twenty subjects (19 subjects completed the study) read a short passage from Treasure Island mounted on the wall approximately 1 m from their eyes while wearing left-right reversing prisms. The strobe on time of 3 microseconds and flash frequency of 4 Hz was set to equal that used in the original study. Motion sickness was scored using a modified Miller and Graybiel scale that we constructed to include symptoms that may be elicited under conditions where reversing prisms are worn. On this scale a score of 5 represented Malaise IIa (mild motion sickness) and a score of 8 or above is approaching frank sickness. Symptoms were tracked and recorded every 5 min during the task. Testing was limited to 30 min unless the subject had reached the MIIa score, at which time the test was terminated. Performance under stroboscopic illumination was significantly better than when the subjects read under normal room illumination while wearing the left-right reversing prisms. Based on these results we developed a goggle system using LCD material that can be strobed. To evaluate the effectiveness of stroboscopic goggles we tested an additional 9 subjects in addition to retesting 10 used in the stroboscopic pilot study described above. These 19 subjects wore a pair of strobing LCD goggles that could be cycled at 4 Hz. These subjects wore the goggles while also wearing left-right reversg prisms. Results while wearing the goggles showed that none of the 19 subjects scored at the MIIa level on the motion sickness rating scale. When the goggles did not flash (no strobe), 11 of the 19 developed symptoms above the MIIa criteria. As a countermeasure the goggles seem to be effective, even with an on time of 10 msec (time the goggles are clear). We have also collected anecdotal data, from our personnel in the Neuroscience Laboratory at the Johnson Space Center, suggesting that the goggles may effective in preventing carsickness.

Reschke, M. F.↗

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↗