DEPLOYTECH: Deployment Technology Survey Web Publication Version
The information in this survey provides a sample of details on deployable structures that have been proposed, tested, and flown from the 1960s to today.
Russell, Tiffany E.↗
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ATI SAA Annex 3 Button Tensile Test Report I
This report documents the results of a study carried out under Splace Act Agreement SAA-EA-10-004 between the National Aeronautics and Space Administration (NASA) and Astro Technology Incorpporated (ATI). NASA and ATI have entered into this agreement to collaborate on the development of technologies that can benefit both the US government space programs and the oil and gas industry. The report documents the results of a test done on an adnesive system for attaching new monitoring sensor devices to pipelines under Annex III of SAA-EA-10-004: "Proof-of-Concept Design and Testing of a Post Installed Sensing Device on Subsea Risers and Pipelines". The tasks of Annex III are to design and test a proof-of-concept sensing device for in-situ installation on pipelines, risers, or other structures deployed in deep water. The function of the sensor device is to measure various signals such as strain, stress and temperature. This study complements the work done, in Annex I of the SAA, on attaching a fiber optic sensing device to pipe via adhesive bonding. Both Annex I and Annex III studies were conducted in the Crew and Thermal System Division (CTSD) at the Johnson Space Center (JSC) in collaboration with ATI.
Tang, Henry H.↗
Solar Thermal Vacuum Test of Deployable Astromesh Reflector
On September 10, 2008, a 36-hour Solar Thermal Vacuum Test of a 5m deployable mesh reflector was completed in JPL's 25' Space Simulator by the Advanced Deployable Structures Group at JPL. The testing was performed under NASA's Innovative Partnership Program (IPP) as a risk reduction effort for two JPL Decadal Survey Missions: DESDynI and SMAP. The 5.0 m aperture Astromesh reflector was provided by Northrop Grumman Aerospace Systems (NGAS) Astro Aerospace, our IPP industry partner. The testing utilized a state-of-the-art photogrammetry system to measure deformation of the reflector under LN2 cold soak, 0.25 Earth sun, 0.5 sun and 1.0 sun. An intricate network of thermocouples (approximately 200 in total) was used to determine the localized temperature across the mesh as well as on the perimeter truss of the reflector. Half of the reflector was in a fixed shadow to maximize thermal gradients. A mobility system was built for remotely actuating the cryo-vacuum capable photogrammetry camera around the circumference of the Solar Simulator. Photogrammetric resolution of 0.025 mm RMS (0.001") was achieved over the entire 5 meter aperture for each test case. The data will be used for thermo-elastic model correlation and validation, which will benefit the planned Earth Science Missions.
Photogrammetry↗
Lightweight Integrated Solar Array (LISA): Providing Higher Power to Small Spacecraft
Affordable and convenient access to electrical power is essential for all spacecraft and is a critical design driver for the next generation of smallsats, including CubeSats, which are currently extremely power limited. The Lightweight Integrated Solar Array (LISA), a concept designed, prototyped, and tested at the NASA Marshall Space Flight Center (MSFC) in Huntsville, Alabama provides an affordable, lightweight, scalable, and easily manufactured approach for power generation in space. This flexible technology has many wide-ranging applications from serving small satellites to providing abundant power to large spacecraft in GEO and beyond. By using very thin, ultraflexible solar arrays adhered to an inflatable or deployable structure, a large area (and thus large amount of power) can be folded and packaged into a relatively small volume.
Johnson, Les↗
Looking Back in Time: Building the James Webb Space Telescope (JWST) Optical Telescope Element
When it launches in 2018, the James Webb Space Telescope (JWST) will look back in time at the earliest stars and galaxies forming in the universe. This talk will look back in time at the development of the JWST telescope. This will include a discussion of the design, technology development, mirror development, wave front sensing and control algorithms, lightweight cryogenic deployable structure, pathfinder telescope, and integration and test program evolution and status. The talk will provide the engineering answers on why the mirrors are made of Beryllium, why there are 18 segments, where and how the mirrors were made, how the mirrors get aligned using the main science camera, and how the telescope is being tested. It will also look back in time at the many dedicated people all over the country who helped build it.
JWST OTE↗
Precision Optical Edges for a Starshade External Occulter
The use of a starshade is one technique to perform high contrast imaging with space-based telescopes. The primary function of a starshade is to suppress light from a target star in order to image its orbiting planets. In order to provide the proper apodization function the edges of the starshade must follow a precise in-plane profile. However of equal importance is the issue of light from our own sun scattering off of the edges and entering the telescope. A method to alleviate this problem is to make the edges extremely sharp (< 1 µmterminal radius) such that the area available for scattering is minimized. The combination of these two requirements, along with the need to integrate the edges into a 30-40 m dia. deployable structure, present a number of significant engineering challenges. Substrate etching techniques are used to obtain both the intended profile as well as the edge sharpness. Current efforts implement an isotropic etching process on thin metal substrates. This paper discusses the progress towards producing a sharp optical edge at the coupon level. Samples have been characterized using scanning electron microscopy as well as a custom testbed to assess their scattered-light performance.
starshade↗
Technology and Opportunities of Photon Sieve CubeSat with Deployable Optical Membrane
A photon sieve (PS) is a revolutionary optical instrument that provides high resolution imaging at a fraction of the weight of typical telescopes, with an areal density of 0.3 kg/m2 compared to 25 kg/m2 for the James Webb Space Telescope. The photon sieve is a variation of a Fresnel Zone Plate consisting of many small holes arranged in a series of concentric rings. The sieve works by diffracting light of a certain wavelength to a specified focal point for imaging, so that only a specific wavelength can be imaged. Moreover, the better image contrast and higher signal-to-noise ratios come from suppressing higher diffracted orders by apodizing the number of pinholes in the outer rings. Finally, a photon sieve requires less supports and can withstand more deformation without a reduction in the imaging qualities. Due to these properties, various groups have created PS CubeSats for Earth and Sun imaging at a low cost and weight specifically using deployable technology. A team at the Air Force Research Laboratory created a design and prototype of a mechanism that deploys a 20 cm diameter photon sieve. The United States Air Force Laboratory used a similar design to create a CubeSat-based deployable photon sieve. The team at NASA Langley Research Center has researched photon sieves for conducting an Earth-observing experiment using LIDAR (Light Detection and Ranging) with a higher signal-to-noise ratio benefit from the PS. This paper provides a state of the art overview on existing PS CubeSat technology with deployable structures and applications. Especially, the paper introduces PS for LIDAR applications and discusses the CubeSat-based PS challenge being worked at the NASA Langley Research Center.
Hyun Jung Kim↗
Space Technology for Directly Imaging and Characterizing Exo-Earths
The detection of Earth-like exoplanets in the habitable zone of their stars, and their spectroscopic characteri- zation in a search for biosignatures, requires starlight suppression that exceeds the current best ground-based performance by orders of magnitude. The required planet/star brightness ratio of order 10-10 at visible wave-lengths can be obtained by blocking stellar photons with an occulter, either externally (a starshade) or internally (a coronagraph) to the telescope system, and managing diffracted starlight, so as to directly image the exoplanet in reflected starlight. Coronagraph instruments require advancement in telescope aperture (either monolithic or segmented), aperture obscurations (obscured by secondary mirror and its support struts), and wavefront error sensitivity (e.g. line-of-sight jitter, telescope vibration, polarization). The starshade, which has never been used in a science application, benefits a mission by being decoupled from the telescope, allowing a loosening of telescope stability requirements. In doing so, it transfers the difficult technology from the telescope system to a large deployable structure (tens of meters to greater than 100 m in diameter) that must be positioned precisely at a distance of tens of thousands of kilometers from the telescope. We describe in this paper a roadmap to achieving the technological capability to search for biosignatures on an Earth-like exoplanet from a future space telescope. Two of these studies, HabEx and LUVOIR, include the direct imaging of Earth-sized habitable exoplanets as a central science theme.
Crill, Brendan P.↗
ADEPT Sounding Rocket One (SR-1) Flight Test
A sounding rocket flight test was conducted on a mechanically-deployed entry vehicle (DEV) known as the Adaptable Deployable Entry and Placement Technology (ADEPT). This flight test was a major milestone in a technology development campaign for ADEPT: the application of ADEPT for small secondary payloads. The test was conducted above White Sands Missile Range (WSMR), New Mexico on a SpaceLoft XL rocket on September 12, 2018. The first objective of the SR-1 flight test was to demonstrate that ADEPT could transform from a compact stowed configuration, separate from the launch vehicle, and successfully deploy exo-atmospherically into the desired low ballistic coefficient entry configuration. The second objective was to characterize the aerodynamic performance of the deployed configuration in order to evaluate the faceted blunt body geometry dynamic stability characteristics as it decelerated from supersonic to subsonic speeds.The ADEPT DEV had several sensors on-board and also leveraged third-party data sources for post-flight analysis and trajectory reconstruction. Based upon data review, the launch vehicle met exo-atmospheric delivery performance requirements of spin rate, no re-contact, separation velocity, and delivery altitude. The unique ADEPT forebody geometry (blunted octagonal pyramid, 0.7 m diameter at the rib tips) and aftbody configuration has never flown before. The forebody half cone angle at the ribs is 70 deg, while the half cone angle mid gore is 68.5 deg. The aftbody, where the 3U CubeSat 'payload' resides is a rectangular prism that extends ~ ½ the minimum forebody diameter behind the nose. Understanding DEV blunt body dynamic stability performance is critical for determining how they can be employed for atmospheric entry, descent and landing.The primary data products were used to perform flight mechanics analysis and reconstruct the as-flown trajectory. On-board video recovered post-flight demonstrated that the DEV achieved and maintained the desired entry configuration. Post-flight analyses showed that the vehicle met the threshold of achieving stable flight below Mach = 0.8. The ADEPT project has focused on ballistic, axisymmetric shapes as the logical 'first step' in mission infusion applications. With the current maturation and development of the ballistic (non-lifting) 1 m class ADEPT, the next step in ADEPT maturation is the focus on configurations that are capable of generating lift in order to accomplish aerocapture and precision landing mission capabilities. ADEPT is particularly attractive for evaluating various guidance and control approaches as the deployable structure enables attachment points for various actuation methods such as control surfaces, moving mass elements, or RCS thrusters. The ADEPT sounding rocket flight test provided a low-cost means of achieving significant system level maturity for the 1 m class ADEPT configuration. A description of the technology, system components, flight test execution, and conclusions will be described.
Cassell, Alan↗
Pterodactyl: Control System Demonstrator Development for Integrated Control Design of a Mechanically Deployed Entry Vehicle
The NASA-funded Pterodactyl project is a design, test, and build capability to (i) advance the current state of the art for Deployable Entry Vehicle (DEV) guidance and control (G&C), and (ii) determine the feasibility of control system integration for various entry vehicle types including those without aeroshells. This capability is currently being used to develop control systems for one such unconventional entry vehicle, the Lifting Nano-ADEPT (LNA) vehicle. ADEPT offers the possibility of integrating control systems directly onto the mechanically deployed structure and building hardware demonstrators will help assess integration and design challenges. Control systems based on aerodynamic control surfaces, mass movement, and reaction control systems (RCS) are currently being investigated for a down-select to the most suitable control architecture for the LNA.To that effect, in this submission, we detail the efforts of the Pterodactyl project to develop a series of hardware demonstrators for the different LNA control systems. Rapid prototypes, for a set of quarter- model or eighth-model vehicle segments, will be developed for all three architectures to validate mechanical design assumptions, and hardware-in-the-loop (HIWL) control approaches. A ground test control system demonstrator will be designed and built after the trade study is complete. The industrial-grade demonstrator will be designed so that it can be incorporated into a HWIL simulation to further validate the findings of the initial trade study. The HWIL simulation will leverage the iPAS environment developed at NASA's Johnson Space Center which facilitates integration testing to support technology maturation and risk reduction, necessary elements for the hardware demonstration development detailed in this paper.
Margolis, Benjamin W.↗
Transformational Solar Array Option I Final Report
This report summarizes the work performed under NASA contract NNC16CA19C from May 2, 2017 through April 2, 2018. This work is directed toward meeting the goals of the associated NASA NRA and, of course, the requirements of the contract. In brief, the goals are: (1) Over 47% beginning of life cell efficiency at 5 AU and -125 °C (2) Over 32% end of life efficiency at the blanket level at 50 W m-2, -125 °C and 4E15 1 MeV e cm-2 (3) Over 8 W kg-1 at EOL for the entire array including structure, deployment, and pointing mechanisms using beginning of life performance. (4) A stowed packaging density of greater than 66 kW m-3 (5) An ability to survive launch and numerous deploy retract cycles without degradation (6) An output higher than 300 V (7) An ability to operate in a plasma generated by xenon thrusters, typically 1E8 cm-3 ions with an average energy of 2 eV (8) A design compatible with electrostatic and magnetic cleanliness (9) Record breaking inverted metamorphic (IMM) 6 junction solar cells (10) IMM solar cells that have no anomalous flat spot behavior at low irradiance and low temperature (11) A mock-up production line for the low-cost manufacture of spacecraft blanket arrays. The Option I phase of the project continued efforts, started in the base-phase, to eliminate or reduce to very low levels the flat spots that reduce power to an unacceptable value in a significant percentage of cells and to reduce outgassing contamination of the concentrators to acceptable levels. Option I adds tasks to increase the efficiency of IMM cells from those produced in the Base Phase, to eliminate delamination of the coatings that were present in previous versions of the concentrator mirrors, to evaluate pressure sensitive adhesive as a method of fixing solar cell assemblies to blankets, to design a magnetically clean brake for ROSA, to test the robustness of a sample blanket in deploy and retract, to test for the adequate performance of a blanket in vibration and thermal environments, and to define the capital equipment needed to optimize production of the Transformational Array. 5 Work for this Final Report showed that the greatest likely improvement in the solar cells would be by emphasizing the effort for the IMM4 solar cells and stopping work on other IMM cells. For this phase, the solar cell work was primarily on the IMM4 cells with little work on IMM5 and none on IMM6 cells.
Gaddy, Edward↗
Advances in Low-Cost Manufacturing and Folding of Solar Sail Membranes
Solar sail membranes must have a high area-to-mass ratio and high solid volume fraction when stowed. In order to meet mission requirements, current solar sail projects, such as NASA’s Near Earth Asteroid Scout, require metallized sail membranes with thicknesses on the order of 2-3 μm. These very thin membranes do not retain creases like thicker membranes, solar panels, or paper models. For Cubesat-class spacecraft, volume, rather than mass, is often the driving requirement for deployable structural elements. These two factors make it both difficult and highly desirable to characterize the practical differences between solar sail membrane packaging methods with laboratory demonstrations. This paper presents lessons gathered from lab work with solar sail membranes at a 10-meter scale.
Stohlman, Olive R.↗
Flexible electronics for space applications
NASA is currently developing a host of deployable structures for the exploration of space. These include balloons, solar sails, space-borne telescopes and membrane-based synthetic aperture radar.
Crawford, Robert↗
Detection and Mitigation of Transient Instabilities in Multi-Agent Systems and Swarms
We first introduce the novel concept of transient instabilities in multi-agent systems and swarms, i.e., a small disturbance leads to increasing-amplitude oscillations throughout the swarm, which results in a large number of inter-agent collisions. This instability is dominant in the transient phase of the system and it does not appear in the steady-state behavior of the system, as each agent uses Lyapunov-stable feedback control laws. We present a rigorous definition of transient instability in swarms, and discuss its key properties. We also present a sufficient condition to check if a swarm will be transient stable. We study the behaviour of different control laws under this condition. We also show how transient instability phenomenon could impact the dynamics of deployable structures. Next, we present a novel control architecture that augments the baseline formation maintenance controller to mitigate transient instabilities. At its heart, the proposed architecture consists of a projection operator based estimator disguised as a reference model that generates collision-free trajectories for the agents to follow. We present numerical simulation results to demonstrate the effectiveness of our proposed approaches.
Quadrelli, Marco B.↗
EDS to the Moon!
The Electrostatics and Surface Physics Laboratory at NASA Kennedy Space Center is slated to send multiple Electrodynamic Dust Shields (EDS) to the surface of the moon. This paper discusses the EDS onboard a Commercial Lunar Payload System or CLPS mission slated to launch to the moon on July 27, 2023 on Firefly Aerospace’s Blue Ghost Lander to Mare Crisium. The EDS payload consists of a camera EDS, a separate glass EDS, a thermal radiator EDS as well as a Re-Duster system based on EDS technology. The EDS will be deposited on the ground by a deployable structure on the lunar lander shortly after touchdown and its operations will take precedence over the other 10 payloads on the lander. The camera will record images and videos of dust deposition and removal on both the Thermal Radiator EDS and the Glass EDS. Data handling will be done using a Data Storage Unit (DSU) developed by NASA Langley Research Center and downlinked to Earth in real time.
Charles R Buhler↗
Multiscale Prediction of Yarn Pullout Failure Mode in Unreinforced Textile Fabrics
Unreinforced woven fabrics have been implemented in a variety of high performance applications, including body armor, deployable structures, and as the reinforcement material in composites. Multiscale modeling techniques have significantly improved the capabilities of simulation-based tools to capture fabric mechanics efficiently and accurately, but often lack in their prediction of failure and require pairing with finite element analysis (FEA) software, limiting their application to the design of ‘fit-for-purpose’ materials. NASA’s Multiscale Analysis Tool (NASMAT) is a standalone multiscale program that has been traditionally used in the analysis of reinforced composites materials. More recently, it has been amended to simulate unreinforced fabric behavior by allowing the geometric state of the tows to change with applied loading due to the lack of a reinforcement material, such as the matrix seen in composites. Previous work has shown the ability of NASMAT to capture nonlinear macroscale behavior by predicting geometric changes in the state of each subcell as a function of the applied loading and allowing each subcell in the analysis to rotate according to these predicted changes, as well as predict nonlinear behavior due to the fiber breakage failure mode. In this work, the capability of predicting the onset and propagation of failure in plain woven fabrics in NASMAT is presented for the yarn pullout failure mode, which occurs when a fabric is loaded at an off-axis angle relative to the warp of weft tow direction. Yarn pullout behavior is initiated by determining the applied load in which the shear resistance of the contact area between yarn families is overcome. When failure is initiated, yarn pullout is determined to have occurred when the applied displacement, calculated from global strain, exceeds the deformed position of a given contact points between yarn families, determined from pin-joint kinematics. Contact points where pullout has occurred contribute to a global damage parameter used to modify the homogenized stiffness of the fabric, resulting in nonlinear behavior observed at the macroscale. The off-axis loading behavior and yarn pullout failure theory have been developed and implemented into NASMAT such that users can simulate off-axis tensile behavior of fabrics in a single, standalone multiscale tool. Simulations are compared to uniaxial tensile tests at various off-axis angles to demonstrate the capability of the tool in its prediction of both the onset of failure at each off-axis angles and the stress-strain behavior as failure progresses.
Materials↗
LOFTID Surface Heating Reconstruction
On November 10, 2022, the Low-Earth Orbit Flight Test of an Inflatable Decelerator (LOFTID) reentry vehicle launched to low-Earth orbit aboard a United Launch Alliance Atlas V rocket out of Vandenberg Air Force Base. The aeroshell, the largest Hypersonic Inflatable Aerodynamic Decelerator (HIAD) ever flown, was inflated to its full 6-meter diameter before successful re-entry into the atmosphere. The aeroshell was heavily instrumented in order to understand its behavior during entry. There were 82 thermocouples (TCs) distributed across the aeroshell, with 22 integrated into the flexible thermal protection system (FTPS) on the rigid nose, 36 in the FTPS on the deployable structure, and 24 on the inflatable structure. TCs were placed at different depths throughout the FTPS. Those nearest to the surface were located just beneath the two SiC outer fabric layers. The near-surface TCs on the rigid nose were Type R with flame spray alumina insulation, while those on the flank were Type N with mica/ceramic insulation. Additionally, a radiometer was placed at the center of the nose surrounded by four total heat flux gauges in a cruciform configuration at a radius of 0.41 m. The nose instrumentation is shown in Fig. 1 and a cross-section of the aeroshell with all TC locations is shown in Fig. 2. The objective of this work was to use the temperatures measured by the TCs during flight to estimate the surface heat rate across the aeroshell throughout the period of re-entry by inverse analysis methodology. The results were used to evaluate the fidelity of measurements from the total heat flux gauges on the nose, determine the surface heat flux at aeroshell locations where gauges were not present, and compare to pre-flight CFD-based heating predictions. Inversely estimated surface heat flux continues to be used to correlate FTPS thermal models to reconstruct in-flight thermal response.
H S Alpert↗
LOFTID Surface Heating Reconstruction
On November 10, 2022, the Low-Earth Orbit Flight Test of an Inflatable Decelerator (LOFTID) reentry vehicle launched to low-Earth orbit aboard a United Launch Alliance Atlas V rocket out of Vandenberg Air Force Base. The aeroshell, the largest Hypersonic Inflatable Aerodynamic Decelerator (HIAD) ever flown, was inflated to its full 6-meter diameter before successful re-entry into the atmosphere. The aeroshell was heavily instrumented in order to understand its behavior during entry. There were 82 thermocouples (TCs) distributed across the aeroshell, with 22 integrated into the flexible thermal protection system (FTPS) on the rigid nose, 36 in the FTPS on the deployable structure, and 24 on the inflatable structure. TCs were placed at different depths throughout the FTPS. Those nearest to the surface were located just beneath the two SiC outer fabric layers. The near-surface TCs on the rigid nose were Type R with flame spray alumina insulation, while those on the flank were Type N with mica/ceramic insulation. Additionally, a radiometer was placed at the center of the nose surrounded by four total heat flux gauges in a cruciform configuration at a radius of 0.41 m. The nose instrumentation is shown in Fig. 1 and a cross-section of the aeroshell with all TC locations is shown in Fig. 2. The objective of this work was to use the temperatures measured by the TCs during flight to estimate the surface heat rate across the aeroshell throughout the period of re-entry by inverse analysis methodology. The results were used to evaluate the fidelity of measurements from the total heat flux gauges on the nose, determine the surface heat flux at aeroshell locations where gauges were not present, and compare to pre-flight CFD-based heating predictions. Inversely estimated surface heat flux continues to be used to correlate FTPS thermal models to reconstruct in-flight thermal response.
LOFTID↗