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NASA NTRS2018

Compact Telescoping Surface Array for Mars Solar Power

This paper describes a lightweight, large-area solar array concept for Mars surface power called the Compact Telescoping Surface Array (CTSA). The design is derived from the Compact Telescoping Array (CTA) proposed in 2015 for high-power spacecraft. The CTSA deploys horizontally from Mars landers, provides 1000 sq.m of solar cell area, and generates about 50-80 kW daytime and 10 kW nighttime power (from energy storage) near the equator with clear skies. The total mass is about 1500 kg, and the stowed volume is about 10 cu.m, equivalent to 200 W/kg and 30 kW/cu.m at 1 astronomical unit (AU) from the sun. These challenging mass and volume goals require compact, lightweight structures to deploy and tension thin solar cell blankets in the Mars 0.38 g gravity field. Other features include single-axis rotation for daily or seasonal sun tracking, dust shedding, and feathering in high winds and sufficient strength for sustained 40 m/s winds in dust storms and brief 100 m/s winds in dust devils (dynamic pressure of 120 Pa). Based on preliminary design and analysis reported in the paper, CTSA appears to be a feasible approach for 1000 sq.m-class Mars solar arrays that autonomously deploy from landers prior to human arrival.

Pappa, Richard↗

NASA NTRS2020

Generation and Calibration of Linear Models of Aircraft with Highly Coupled Aeroelastic and Flight Dynamics

The lightweight structures and unconventional configurations being considered for the next generation of aircraft mean that any effort to predict or control the flight dynamics is impacted by the structural dynamics. One of the most severe forms of coupling between aeroelasticity and flight dynamics is an instability called body freedom flutter. The existing tools often assume a relatively weak effect of structural dynamics on the flight dynamics, and are therefore incapable of modeling strong interactions like body freedom flutter. A method of combining different sources of data traditionally used for aeroelasticity and flight dynamics is described by reconciling many of the differences between these models. By building upon past modeling efforts, a level of familiarity in the approach is achieved. Generally the differences from the traditional approaches are subtle but significant. The traditional frequency domain flutter model in a modal coordinate system is converted to a form consistent with a time domain flight dynamics model. The time domain rational function approximation about a non-inertial coordinate system and the unique constraints for the conversion between the inertial and non-inertial coordinate systems are discussed. A consistent transformation of the states of aeroelastic models to flight dynamics models is derived, which enables the integration of data from higher fidelity computational fluid dynamics models or wind-tunnel testing. The present method of integrating multidisciplinary data was used to create models that compare well with X-56A flight-test data, including conditions past the flutter speed.

Ouellette, Jeffrey↗

NASA NTRSDate not supplied

TPSAS-NF1676L-18391-DND

Vehicle weight is a primary driver for most NASA missions. Reducing vehicle weight can: - Expand mission capability - Reduce launch costs - Reduce fuel consumption - Systems analysis shows that reducing materials mass by 20% leads to a 30% reduction in launch vehicle gross weight - Same study indicates a 50% reduction in materials mass reduces launch vehicle gross weight by >60%, enables potential single stage to orbit designs - Additional multifunctionality: thermal, radiation protection, sensing capabilities, no corrosion Potential Impact: Produce advanced lightweight structural BNNT composites with higher thermal stability, no corrosion, high toughness, sensing/actuation, and radiation shielding effectiveness.

Cheol Park↗

NASA NTRSDate not supplied

Mechanically Strong Polyimide Aerogels (MSPA) As Multifunctional Acoustic Insulation

Aerogel Technologies has an exclusive license from NASA to commercialize polyimide aerogels developed at NASA GRC. They combine low density, low thermal conductivity, high specific strength, and soundproofing properties in a single material envelope. Aerogel Technologies and NASA GRC are working together to optimize the properties for lightweight, structural material for vibro-acoustic mitigation for launch vehicles, with the goal of achieving TRL 6 by the conclusion of the project.

polyimide aerogel↗

NASA NTRSDate not supplied

TriTruss Packaging and Deployment Trade Study

A trade study was conducted that evaluated viable concepts of operation for the packaging and deployment (P&D) of novel deployable modular truss modules, called TriTruss modules, that can be assembled to form a large aperture In-Space Assembled Telescopes (iSAT). In this first phase of an ongoing more comprehensive trade study, concepts were proposed and then evaluated based on initial metrics representing features of an ideal P&D concept. The ideal TriTruss P&D concept is defined as one that: allows for efficient packaging, has sufficient geometric versatility to be launch vehicle independent, provides a stiff and lightweight structure, has low mechanical complexity, and has component modularity. The P&D concept should allow for prelaunch subsystem or utility integration if required. The concept should be kinematically simple and be robotically deployed using a minimum number of specialized tools. The P&D concepts evaluated are categorized as: core collapse, face collapse, and erectable structures. Sub-scale models were constructed to help understand the kinematics and mechanical complexity required to enable P&D. Based on a weighting scale, the most promising candidate P&D concepts have been selected and will undergo more rigorous structural design, analysis, and testing in the study’s next phase. The ultimate goal of the comprehensive trade study will be to recommend a single TriTruss design and associated P&D concept that will be built and evaluated at NASA Langley Research Center’s In-Space Assembly Laboratory.

in-space assembly (ISA)↗

NASA NTRS2000

The Gossamer Initiative

The Gossamer Spacecraft Initiative is a new NASA program to begin long-range development of enabling technologies for very large, ultra-lightweight structures and apertures.

Gossamer↗

NASA NTRSDate not supplied

LSMS–L35, Miniature Crane for Payload Offloading and Manipulation: Development, and Application

The Lightweight Surface Manipulation System (LSMS) is a robotic agent for autonomous surface construction activities on planetary surfaces, that was designed at NASA Langley Research Center and has over a decade of research and development. The LSMS is a key component to achieving many goals of the NASA Artemis program. The LSMS is lightweight, structurally efficient system that can be easily packaged for launch and deployment on-surface, capable of a suite of surface activities enabled by modular end-effectors at the wrist. The focus of recent development work has been on using the LSMS for payload offloading and handling from lunar landers. Discussed in the paper is the development of the LSMS-L35 hardware (35 kg wrist lifting capacity on the lunar surface), designed to integrate with a Commercial Lunar Payload Services (CLPS) lander to offload payloads to the surface. The LSMS-L35 hardware development is part of a larger effort to enable autonomous payload handling and manipulation.

Iok M. Wong↗

NASA NTRSDate not supplied

An Integrated Design Tool for Tow-Steered Laminates of Composites in Abaqus and MSC.Patran/Nastran

Tow-steered composites can be tailored for optimal mechanical performance of lightweight structures. However, there are no commercial-grade design tools for tow-steered composite structures, which hinders the design innovation of tow-steered composites in realistic structures. The novelty of this paper is to develop an integrated design framework along with the development of graphical user interface (GUI) plug-ins in commercial finite element (FE) software Abaqus and MSC.Patran/Nastran. The GUI plug-ins take all the design setups and communicate with external codes for the material modeling and optimization, and hence provide a unified design environment within the FE codes. The mechanics of structure genome (MSG) plate model computes shell element properties based on user-defined fiber paths and layup, which are defined via the GUI plug-ins. The optimization is performed by an open-source code, Dakota, from Sandia National Laboratories (Sandia), which also coordinates the structural analysis, material modeling, and optimization in design iterations. Two examples are presented to demonstrate the user-friendliness and versatility of the developed GUI plug-ins. The developed tools will ease the design process and facilitate the application of tow-steered composites in realistic aerospace structures.

Xin Liu↗

NASA NTRSDate not supplied

An Integrated Design Tool for Tow-Steered Laminates of Composites in Abaqus and MSC.Patran/Nastran

Xin Liu↗

NASA NTRS2024

Investigation of Carbon-Reinforced Acrylonitrile Butadiene Styrene 3D-Printed Honeycomb Composites

The expansive utility of polymeric 3D printing technologies and demand for high-performance lightweight structures has prompted the emergence of various carbon-reinforced polymer composite filaments. However, detailed characterization of the processing-microstructure-property relationships of these materials is still required to realize their full potential. In this study, acrylonitrile butadiene styrene (ABS) and carbon reinforced ABS variants, both carbon nanotubes (CNT) and 5 wt.% chopped carbon fiber (CF), are fabricated in a honeycomb geometry and investigated across a range of layer thicknesses and hex sizes. Microscopy of material cross-sections is conducted to evaluate the relationship between print parameters and porosity. Additionally, mechanical properties are evaluated through compression testing, demonstrating the potential of honeycomb ABS, ABS-CNT, and ABS-5wt.% CF polymer composites for novel 3D printed structures.

ABS (Acrylonitrile Butadiene Styrene)↗

NASA NTRSDate not supplied

Investigation of Carbon-Reinforced Acrylonitrile Butadiene Styrene 3D-Printed Honeycomb Composites

ABS (Acrylonitrile Butadiene Styrene)↗

NASA NTRS2026

Smart Process Planning for Automated Fiber Placement

Many industries, including aerospace, automotive, wind energy, maritime, and sporting goods, rely on strong, lightweight materials called composites. These materials are made by layering fibers, which can come in the form of narrow strips or wider sheets, and setting them in a polymer matrix. One of the most advanced ways to make these parts is through automated fiber placement, where a machine lays down the fibers in precise patterns. This method can create very efficient and strong designs, but it is complex, expensive, and often depends heavily on the experience of skilled engineers. Today, the design, manufacturing, and inspection stages of composite production are usually handled separately. This separation means that important information, such as how a part will be built or what defects might occur, is not always shared between stages. As a result, parts may not be as lightweight, strong, or defect-free as possible, and the process can take longer and cost more. This research develops a smart process planning system that connects design, manufacturing, and inspection into one continuous process. Built as software that works with existing tools, the system can automatically plan how the fibers are placed, predicting and reducing defects while improving both manufacturability and strength. The system optimizes not only individual layers but also how defects are distributed across all layers, preventing them from stacking up in ways that weaken the final part. It also uses inspection results from completed parts to improve future designs, creating a feedback loop where each stage informs the others. The system was tested by designing a composite panel using this new approach and comparing it to a panel made with state-of-the-art manual planning methods. The results showed that the system could intentionally control where defects appeared and increase the efficiency of the planning process. By unifying design, manufacturing, and inspection, this research shows a way to make advanced composite manufacturing more efficient, consistent, and cost-effective. This approach lowers the barrier to using automated fiber placement and opens the door for its wider adoption not only in aerospace but also in industries such as automotive, wind energy, maritime, and sporting goods, where strong and lightweight structures are essential.

Computer-Aided Process Planning↗

NASA NTRS2001

Structural Dynamics Experimental Activities in Ultra-Lightweight and Inflatable Space Structures

This paper reports recently completed structural dynamics experimental activities with new ultralightweight and inflatable space structures (a.k.a., "Gossamer" spacecraft) at NASA Langley Research Center, NASA Marshall Space Flight Center, and NASA Goddard Space Flight Center. Nine aspects of this work are covered, as follows: 1) inflated, rigidized tubes, 2) active control experiments, 3) photogrammetry, 4) laser vibrometry, 5) modal tests of inflatable structures, 6) in-vacuum modal tests, 7) tensioned membranes, 8) deployment tests, and 9) flight experiment support. Structural dynamics will play a major role in the design and eventual in-space deployment and performance of Gossamer spacecraft, and experimental R&D work such as this is required now to validate new analytical prediction methods. The activities discussed in the paper are pathfinder accomplishments, conducted on unique components and prototypes of future spacecraft systems.

Pappa, Richard S.↗

NASA NTRS2001

Pathfinder Photogrammetry Research for Ultra-Lightweight and Inflatable Space Structures

The defining characteristic of ultra-lightweight and inflatable space structures is that they are both very large and very low mass. This makes standard contacting methods of measurement (e.g. attaching accelerometers) impractical because the dynamics of the structure would be changed by the mass of the contacting instrument. Optical measurements are therefore more appropriate. Photogrammetry is a leading candidate for the optical analysis of gossamer structures because it allows for the measurement of a large number of points, is amenable to time sequences, and offers the potential for a high degree of accuracy. The purpose of this thesis is to develop the methodology and determine the effectiveness of a photogrammetry system in measuring ultra-lightweight and inflatable space structures. The results of this thesis will be considered in the design of an automated photogrammetry system for the l6m-diameter vacuum chamber at the NASA Langley Research Center.

Giersch, Louis Roy Miller↗

NASA NTRS1971

Fabrication development of lightweight honeycomb-sandwich structures for extraterrestrial planetary probe missions

Lightweight resin fiber glass honeycomb sandwich structure fabrication and comparison with aluminum structures for planetary probes

Boundy, R. A.↗

NASA NTRS1986

An Investigation of Energy Transmission Due to Flexural Wave Propagation in Lightweight, Built-Up Structures

A technique to measure flexural structure-borne noise intensity is investigated. Two accelerometers serve as transducers in this cross-spectral technique. The structure-borne sound power is obtained by two different techniques and compared. In the first method, a contour integral of intensity is performed from the values provided by the two-accelerometer intensity technique. In the second method, input power is calculated directly from the output of force and acceleration transducers. A plate and two beams were the subjects of the sound power comparisons. Excitation for the structures was either band-limited white noise or a deterministic signal similar to a swept sine. The two-accelerometer method was found to be sharply limited by near field and transducer spacing limitations. In addition, for the lightweight structures investigated, it was found that the probe inertia can have a significant influence on the power input to the structure. In addition to the experimental investigation of structure-borne sound energy, an extensive study of the point harmonically forced, point-damped beam boundary value problem was performed to gain insight into measurements of this nature. The intensity formulations were also incorporated into the finite element method. Intensity mappings were obtained analytically via finite element modeling of simple structures.

Mickol, John Douglas↗

NASA NTRS1993

Lightweight solar concentrator structures, phase 2

This report summarizes the results of the program conducted by Ultramet under SBIR Phase 2 Contract NAS3-25418. The objective of this program was to develop lightweight materials and processes for advanced high accuracy Space Solar Concentrators using rigidized foam for the substrate structure with an integral optical surface.

Williams, Brian E.↗

NASA NTRS2002

Microwave-Driven Multifunctional Capability of Membrane Structures

A large, ultra lightweight space structure, such as solar sails and Gossamer spacecrafts, requires a distributed power source to alleviate wire networks, unlike the localized on-board power infrastructures typically found in most small spacecrafts. The concept of microwave-driven multifunctional capability for membrane structures is envisioned as the best option to alleviate the complexity associated with hard-wired control circuitry and on-board power infrastructures. A rectenna array based on a patch configuration for high voltage output was developed to drive membrane actuators, sensors, probes, or other devices. Networked patch rectenna array receives and converts microwave power into a DC power for an array of smart actuators. To use microwave power effectively, the concept of a power allocation and distribution (PAD) circuit is adopted for networking a rectenna/actuator patch array. The use of patch rectennas adds a significant amount of rigidity to membrane flexibility and they are relatively heavy. A dipole rectenna array (DRA) appears to be ideal for thin-film membrane structures, since DRA is flexible and light. Preliminary design and fabrication of PAD circuitry that consists of a few nodal elements were made for laboratory testing. The networked actuators were tested to correlate the network coupling effect, power allocation and distribution, and response time.

Choi, Sang H.↗