Search NASA⌕ Search

SEARCH · Search NASA

Results for “Continuous manufacturing”

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.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 271 records · Page 15
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Interlaboratory Study: Testing Reproducibility of Solid Biofuels Component Identification Using Reflected Light Microscopy

Considering global market trends and concerns about climate change and sustainability, increased biomass use for energy is expected to continue. As more diverse materials are being utilized to manufacture solid biomass fuels, it is critical to implement quality assessment methods to analyze these fuels thoroughly. One such method is reflected light microscopy (RLM), which has the potential to complement and enhance current standard testing, leading to improving fuel quality assessment and, ultimately, preventing avoidable air pollution. An interlaboratory study (ILS) was conducted to test the reproducibility of biomass fuels component identification using a reflected light microscopy technique. The exercise was conducted on thirty photomicrographs showing biomass and various undesired components (like plastics or mineral matter), which were purposely added (by the ILS organizers) to contaminate wood pellets and charcoal-based grilling fuels. Forty-six participants had various levels of difficulty identifying the marked components, and as a result, the percentage of correct answers ranged from 52.2 to 94.4%. Among the most difficult components to distinguish were petroleum products and inorganic matter. Various reasons led to the misidentification, including insufficient morphological descriptions of the components provided to participants, ambiguities of the nomenclature, limitations of the analytical and exercise method, and insufficient experience of the participants. Overall, the results indicate that RLM has the potential to enhance the quality assessment of biomass fuels. However, they also demonstrate that the petrographic classification used in this exercise requires further refinement before it can be standardized. While a new simplified classification of solid biomass fuels components was created as an outcome of this study, future research is necessary to refine the nomenclature, develop a microscopic morphological description of the components, and verify the accuracy of component identification with a follow-up ILS.

biomass↗
DOE OSTI2023

Quantification of SARS-CoV-2 spike protein expression from mRNA vaccines using isotope dilution mass spectrometry

The advent of mRNA vaccine technology has been vital in rapidly creating and manufacturing COVID-19 vaccines at an industrial scale. To continue to accelerate this leading vaccine technology, an accurate method is needed to quantify antigens produced by the transfection of cells with a mRNA vaccine product. This will allow monitoring of protein expression during mRNA vaccine development and provide information on how changes to vaccine components affects the expression of the desired antigen. Developing novel approaches that allow for high-throughput screening of vaccines to detect changes in antigen production in cell culture prior to in vivo studies could aid vaccine development. Here, we have developed and optimized an isotope dilution mass spectrometry method to detect and quantify the spike protein expressed after transfection of baby hamster kidney cells with expired COVID-19 mRNA vaccines. Five peptides of the spike protein are simultaneously quantified and provide assurance that protein digestion in the region of the target peptides is complete since results between the five peptides had a relative standard deviation of less than 15 %. In addition, two housekeeping proteins, actin and GAPDH, are quantified in the same analytical run to account for any variation in cell growth within the experiment. IDMS allows a precise and accurate means to quantify protein expression by mammalian cells transfected with an mRNA vaccine.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2025

Bismuth-oxo Clusters for Next Generation Extreme Ultraviolet Light Photolithography

Photolithography is the primary technique used for the patterning of semiconducting materials for chip manufacturing; however, as requisite pattern dimensions and feature sizes continue to decrease, state-of-the-art lithographic methods now require the use of 13.5 nm extreme ultraviolet (EUV) light. The shift toward these higher energy wavelengths of light has resulted in a need for new single component materials, with high EUV absorption cross sections and high etch resistance. Herein, we report the exploration of Bi 9 O 7 (hfac) 13 as the first bismuth oxo cluster based EUV photoresist. It was determined this material has an exceptional EUV linear absorption coefficient (24 μm –1 ), nearly an order of magnitude larger than commercially available chemically amplified resists (CARs) (∼5 μm –1 ). Additionally, the resist was determined to be highly sensitive to EUV exposure and displayed a dose-to-gel of 10 mJ/cm 2 , undergoing ligand decomposition during exposure and cross-linking during the postexposure bake, which was supported by FTIR and residual gas analysis. In conclusion, this class of bismuth-oxo cluster resists can lead to the development of more efficient, effective and safe EUV resist materials required for next-generation photolithography.

MacKenzie, Harvey K. [Univ. of Victoria, BC (Canad↗
DOE OSTI2022

Versatile acid solvents for pristine carbon nanotube assembly

Chlorosulfonic acid and oleum are ideal solvents for enabling the transformation of disordered carbon nanotubes (CNTs) into precise and highly functional morphologies. Currently, processing these solvents using extrusion techniques presents complications due to chemical compatibility, which constrain equipment and substrate material options. Here, we present a novel acid solvent system based on methanesulfonic or p-toluenesulfonic acids with low corrosivity, which form true solutions of CNTs at concentrations as high as 10 g/liter (≈0.7 volume %). The versatility of this solvent system is demonstrated by drop-in application to conventional manufacturing processes such as slot die coating, solution spinning continuous fibers, and 3D printing aerogels. Through continuous slot coating, we achieve state-of-the-art optoelectronic performance (83.6 %T and 14 ohm/sq) at industrially relevant production speeds. This work establishes practical and efficient means for scalable processing of CNT into advanced materials with properties suitable for a wide range of applications.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2025

Vexcel Imaging's Suitability for Automatic Verification

Accurate, independently verified geospatial data is essential for automated calibration, validation, and operational decision-making. This study evaluated the positional accuracy of Vexcel Imaging™’s UltraCam® Osprey imagery (7.5 cm GSD) using globally distributed Continuously Operating Reference Stations (CORS) as independent control. Despite manufacturer claims of 15 cm horizontal accuracy, residual errors were consistently one to two orders of magnitude larger, with no subset of imagery meeting precision thresholds. These discrepancies cannot be explained by normal photogrammetric or environmental factors and raise concerns about the reliability of the imagery for high-precision tasks. The results demonstrate that Vexcel imagery, in its current form, is unsuitable for workflows requiring rigorous spatial accuracy or automated verification. At the same time, the reproducible validation framework developed in this study establishes a scalable method for assessing commercial imagery, ensuring that future products can be independently and objectively verified before operational adoption.

47 OTHER INSTRUMENTATION↗
DOE OSTI2025

Using low cost, bio-derived and recycled materials in advanced scalable small- and medium- wind turbine manufacturing

In partnership with Bergey Windpower, this project explored the use of recyclable and recycled materials in small- to medium-wind turbine blades (WTBs). A recyclable epoxy resin and infusible thermoplastic resin were investigated using identical fiber reinforcements and manufacturing practices used as Bergey, and the substitution of continuous virgin glass fiber (GF) layers with recycled nonwoven GF (rGF, NW) mats was trialed. The alternative resins both showed very promising performance in terms of static tensile and flexural behavior as well as thermal properties and fatigue behavior in comparison with that of the incumbent materials used at Bergey. The NW rGF materials, however, were found to be a poor substitute for the continuous GF materials for two primary reasons. Firstly, the NW mats took up significantly more resin than their continuous counterparts, which would increase both the weight and the cost of the WTBs. Additionally, an unexpected reaction occurred between the rGF and epoxy materials that resulted in a highly porous, foamed structure. The foaming phenomenon was not observed with the rGF NW and infusible thermoplastic material, but the resin uptake was still prohibitively high. Based on the results of this study, recyclable infusible resins could be viable candidate materials for Bergey in the future. The foaming reaction with the rGF NW mats could prove highly useful in other applications requiring structural foams and has been used to produce demonstrative sandwich panels.

17 WIND ENERGY↗
DOE OSTI2026

DER Cybersecurity Standards: Assessment and Gap Analysis

The purpose of this report is to share the comprehensive gap analysis of existing cybersecurity standards applicable to Distributed Energy Resources (DERs) within the electric power sector. This analysis aims to identify critical deficiencies in current standards, assess their alignment with industry needs, and provide actionable recommendations for enhancing cybersecurity measures. The scope encompasses various DER technologies, including solar, wind, energy storage, and hydrogen fuel cells, and emphasizes the significance of establishing robust cybersecurity frameworks and standards to safeguard these increasingly integrated systems. The report provides valuable insights for stakeholders in the DER ecosystem, including manufacturers, utilities, and regulators. It underscores the importance of continued development and refinement of cybersecurity standards to keep up with the technical advances in DERs and associated cybersecurity challenges. The analysis evaluated IEC, IEEE, ISA, ISO, and UL standards relevant to DER cybersecurity. Standards were assessed on their coverage of key requirements including data availability, integrity, confidentiality, access control, authentication, encryption, and system hardening. For each standard, the analysis assessed its alignment with current industry practices, regulatory compliance, effectiveness in addressing known risks, coverage of emerging risks, and how it promotes interoperability. The evaluation also considered potential integration challenges and barriers to adoption.

97 MATHEMATICS AND COMPUTING↗
NASA NTRS1972

Analytical and experimental investigation of aircraft metal structures reinforced with filamentary composites. Phase 2: Structural fatigue, thermal cycling, creep, and residual strength

Specimens representative of metal aircraft structural components reinforced with boron filamentary composites were manufactured and tested under cyclic loading, cyclic temperature, or continuously applied loading to evaluate some of the factors that affect structural integrity under cyclic conditions. Bonded, stepped joints were used throughout to provide composite-to-metal transition regions at load introduction points. Honeycomb panels with titanium or aluminum faces reinforced with unidirectional boron composite were fatigue tested at constant amplitude under completely reversed loading. Results indicated that the matrix material was the most fatigue-sensitive part of the design, with debonding initiating in the stepped joints. However, comparisons with equal weight all-metal specimens show a 10 to 50 times improved fatigue life. Fatigue crack propagation and residual strength were studied for several different stiffened panel concepts, and were found to vary considerably depending on the configuration. Composite-reinforced metal specimens were also subjected to creep and thermal cycling tests. Thermal cycling of stepped joint tensile specimens resulted in a ten percent decrease in residual strength after 4000 cycles.

Blichfeldt, B.↗
NASA NTRS1975

Extractable resources

The use of information from space systems in the operation of extractive industries, particularly in exploration for mineral and fuel resources was reviewed. Conclusions and recommendations reported are based on the fundamental premise that survival of modern industrial society requires a continuing secure flow of resources for energy, construction and manufacturing, and for use as plant foods.

Source record↗
NASA NTRS1978

On humanity's role in space

Manned spaceflight is considered within the framework of two broad categories: human exploitation of space for economic or scientific gain, and human habitation of space as a place where man may live, grow, and actualize himself. With the advent of the Space Shuttle, exploitation of space will take the form of new product development. This will continue during the 1990s as the new products are manufactured on a scale large enough to be profitable. The turn of the century should see major industries in space, and large space habitats. Thus, the question of mankind's existential needs arises. In addition to basic physical needs, the spiritual and cultural requirements of human beings must be considered. The impact of man's presence in space upon human culture in general is discussed with reference to international cooperation, public interest in space programs, scientific advancement, the basic urge to explore, and the density of mankind as a whole; which will become free of external constraints as we step into the cosmos.

Von Puttkamer, J.↗
NASA NTRS1979

The initial lunar supply base

The first lunar supply base should have a mass less than 1000 tons, be deployed by 24 persons in 4 months, and be maintained by 10 persons. Output could be expanded 20 times in 5 years to 600,000 tons/yr by a factor of 10 expansion of the area of the solar array on the lunar surface, using low power soil beneficiation, increasing the fleet of mining vehicles, and illuminating the base continuously at night with lunar orbiting mirrors. The space manufacturing facility (SMF) will supply most of the mass (solar cells and orbiting mirrors) necessary for expansion. Several devices and procedures are suggested for development which could further reduce the total mass necessary to transport to the Moon to establish the initial lunar supply base.

Criswell, D.↗
NASA NTRS1972

Polymeric compositions and their method of manufacture

Filled polymer compositions are made by dissolving the polymer binder in a suitable sublimable solvent, mixing the filler material with the polymer and its solvent, freezing the resultant mixture, and subliming the frozen solvent from the mixture from which it is then removed. The remaining composition is suitable for conventional processing such as compression molding or extruding. A particular feature of the method of manufacture is pouring the mixed solution slowly in a continuous stream into a cryogenic bath wherein frozen particles of the mixture result. The frozen individual particles are then subjected to the sublimation.

Moser, B. G.↗
NASA NTRS1989

Strut-node joint conjugates for the assembly of semi-permanent or reusable truss structures

When strut and node components are used for truss construction an assembly problem occurs if a strut must be fitted between nodes whose separation distance is either closer or farther than the design intended. This condition is the result of normal dimensional variations that occur in any manufacturing process. In such circumstances two actions would permit continued assembly: change the effective strut length, and move the nodes. Assuming continued assembly is the most attractive alternative, attention is focused on accomplishing these actions as part of the assembly process.

Brewer, W. V.↗
NASA NTRS1989

Tool and equipment requirements for human habitation of Mars

This paper presents an examination of requirements and design considerations for tools and equipment to establish a continuous human presence on Mars. Specific problems addressed include; manufacturing in zero gravity conditions, with or without an atmosphere, temperature considerations, and use of tools by astronauts on Mars or while traveling to or from Mars. A design for a salvage concept for equipment landed on Mars is presented.

Thornton, Michael G.↗
NASA NTRS1993

Continuous Measurement Of Mass Density Of Yarn

Prototype instrument provides measurement data from which one computes mass density of strand of yarn. Includes fixtures placing known length of yarn under known tension across fixed and movable support. Transverse vibrations induced in yarn by moving movable support up and down. Source of light illuminates photodetector at midlength of yarn, and photodetector senses repeated shadowing caused by vibration of yarn through light, thereby measuring vibrations. Also used for continuous real-time monitoring of such yarn-manufacturing processes as coating or impregnation.

Hinkley, Jeffrey A.↗
DOE OSTI2023

Investigating Marine Environmental Degradation of Additive Manufacturing Materials for Renewable Energy Applications: Preprint

Marine renewable energy is a relatively young industry where there is a great need for rapid prototyping in design-build-test campaigns to quickly mature groundbreaking technologies. Additive manufacturing has an important role to play in the industry; however, little information is available to marine energy developers to help inform them on which additive manufacturing materials are appropriate for harsh marine environments. This paper presents an initial study on the mechanical characterization of polymeric additive manufacturing materials and the degradation effects of marine environments. Ultem 9085, acrylonitrile styrene acrylate, and chopped carbon-filled nylon, as well as continuous carbon and glass fiber-reinforced nylon were chosen for this study. Samples were manufactured to perform a variety of tension, shear, and compression mechanical characterization tests on the materials. Half of the samples were conditioned in Pacific Ocean water for approximately 6 months at Pacific Northwest National Laboratory's Marine Sciences Laboratory before being returned for mechanical characterization. The mechanical testing results showed that the Ultem 9085 and acrylonitrile styrene acrylate materials experienced little to no degradation in stiffness or strength after exposure to the marine environment. On the other hand, the nylon-based materials suffered significant stiffness and strength degradation (over 50% in some cases) after environmental conditioning. Ultimately, these data sets should serve as starting points to allow marine renewable energy developers to make informed additive manufacturing material choices for their prototype deployments.

additive manufacturing↗
DOE OSTI2022

Tailoring thermal insulation architectures from additive manufacturing

Abstract Tailoring thermal transport by structural parameters could result in mechanically fragile and brittle networks. An indispensable goal is to design hierarchical architecture materials that combine thermal and mechanical properties in a continuous and cohesive network. A promising strategy to create such a hierarchical network targets additive manufacturing of hybrid porous voxels at nanoscale. Here we describe the convergence of agile additive manufacturing of porous hybrid voxels to tailor hierarchically and mechanically tunable objects. In one strategy, the uniformly distributed porous silica voxels, which form the basis for the control of thermal transport, are non-covalently interfaced with polymeric networks, yielding hierarchic super-elastic architectures with thermal insulation properties. Another additive strategy for achieving mechanical strength involves the versatile orthogonal surface hybridization of porous silica voxels retains its low thermal conductivity of 19.1 mW m −1 K −1 , flexible compressive recovery strain (85%), and tailored mechanical strength from 71.6 kPa to 1.5 MPa. The printed lightweight high-fidelity objects promise thermal aging mitigation for lithium-ion batteries, providing a thermal management pathway using 3D printed silica objects.

36 MATERIALS SCIENCE↗
DOE OSTI2022

3D Printing at Los Alamos

At Los Alamos National Laboratory (LANL), their additive manufacturing division is seeking to answer the question whether it is possible to 3D print on a 5th axis. The end goal is to achieve true continuous fiber 3D printing. My goal on this project was to learn about additive manufacturing, and to learn how to operate the experimental 3D printer. Each print that was done demonstrated a different pattern that would change the strength and integrity of the print. Overall prints with minimal strand separation and featured weave-like patterns proved to have the best integrity.

42 ENGINEERING↗