SEARCH · Search NASA

Results for “Cost Reduction”

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.

SourceResearch connectionFrom yearThrough year

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

At least 271 records · Page 15

All sources NASA NTRS DOE OSTI

DOE OSTI2025

Benefits Of Automated Construction And Energy Efficiency Measures In Modular Homes

This article builds on and adds to a Buildings XV publication that introduced the Transformative Efficiency and Automation in Modular Homes (TEAMH) project. The TEAMH project sought to develop a scalable solution for producing modular homes with 20-50% energy savings and similar cost relative to site-fabricated single-family home construction. A key aspect of the project was assessing the potential for labor cost reductions through automation-assisted construction using light gauge steel (LGS). To quantify the advantages of this approach, side-by-side comparisons were made between traditional wood-framed construction and automation-assisted LGS construction. This demonstration involved constructing one wood-framed wall and several LGS test walls, accompanied by a time-and-motion study. The results indicated that automation assistance could decrease construction time and associated labor costs by as much as 46%. High-performance envelope technologies for exterior insulation and air sealing were evaluated to compare modular homes with site-built homes that meet the International Energy Conservation Code (IECC). A key technology considered was vacuum insulation panels (VIPs) with fiberglass cores. Guarded hot box testing of multiple full-scale wall assemblies containing different combinations of exterior continuous insulation systems containing phenolic foam and VIPs. Testing on various full-scale wall assemblies revealed that, with LGS construction, cavity insulation had minimal impact on exterior wall performance. Omitting cavity insulation can reduce labor and material costs while streamlining manufacturing, as its installation is labor-intensive and not easily automated due to the need for precise placement around wiring and other internal components. Guarded hot box tests of multiple LGS test walls with foam and VIP-based exterior insulation systems achieved R-values of up to 31 hr-ft2-°F/Btu. Finally, building energy modeling of multiple modular home designs indicated that the upgraded envelope assemblies can yield heating energy savings of up to 50% and cooling energy savings of up to 30% compared to IECC 2018 standards.

Shrestha, Som [ORNL] (ORCID:0000000183993797)↗

DOE OSTI2024

Power Electronics Manufacturing Improvements for Heavy-Duty Fuel Cell Vehicles

The Marel Power Solutions project, funded by the U.S. Department of Energy under Award DE-SC0023801, focused on advancing manufacturing techniques for power electronics in heavy-duty fuel cell vehicles. The research aimed to enhance system efficiency, reduce costs, and support broader adoption of hydrogen fuel cell technology. Key areas of investigation included power topology, thermal modeling, system architecture, and accessibility through software tools. Key Accomplishments: 1. Power Topology: - Developed an interleaved boost converter with optimized phase count, leveraging Marel’s proprietary Power Stacks. - Achieved reduced parasitic inductance and resistance, enabling high efficiency in DC-DC converters. 2. Thermal Modeling: - Integrated innovative cooling systems into compact Silicon Carbide (SiC) modules. - Simulations demonstrated the ability to dissipate significant heat (up to 7.5 kW), ensuring device reliability under heavy loads. 3. System Architecture: - Utilized simulation tools to analyze the impact of various fuel cell and vehicle parameters on efficiency. - Highlighted the role of smaller, modular improvements, such as enhanced DC-DC converters, in achieving system-wide gains. 4. Accessibility: - Evaluated and implemented MATLAB/Simulink code generation tools for real-world hardware applications. - Demonstrated the potential for rapid prototyping of custom power systems with reduced development costs. Impact and Benefits: - Efficiency and Cost Reduction: Marel’s cooling technology enhances SiC die performance, reducing the number of dies required and overall system size. - Scalability and Flexibility: The innovations support tailored solutions for diverse applications, from mass transit to mining vehicles. - Sustainability: The research promotes the integration of electrification technologies, helping meet rising energy demands sustainably. Conclusion: The project’s outcomes advance the state of power electronics for hydrogen fuel cell vehicles, enabling more efficient, compact, and cost-effective solutions. These developments lay a foundation for future innovation, contributing to the broader adoption of clean energy technologies in transportation and other industries.

08 HYDROGEN↗

NASA NTRS1976

A fixed collector employing reversible vee-trough concentrator and a vacuum tube receiver for high temperature solar energy systems

A solar heat collection system employing non-tracking reflectors integrated with a fixed vacuum tube receiver which achieves modest year-round concentration (about 2) of the sunlight at low capital costs is discussed. The axis of the vee-trough reflector lies in a east-west direction and requires reversal of the reflector surfaces only twice a year without disturbing the receiver tubes and associated plumbing. It collects most of the diffuse flux. The vacuum tube receiver with selective absorber has no convection losses while radiation and conduction losses are minimal. Significant cost reductions are offered since the vee-trough can be fabricated from inexpensive polished or plastic reflector laminated sheet metal covering 2/3 of the collection area, and only about 1/3 of the area is covered with the more expensive vacuum tube receivers. Thermal and economic performance of the vee-trough vacuum tube system, year-round variation of the concentration factor, incident flux, useful heat per unit area at various operation temperatures and energy cost estimates are presented. The electrical energy cost is estimated to be 77 mills/kWh, and the system construction cost is estimated to be $1140/kWe.

Selcuk, M. K.↗

DOE OSTI2024

The Cost of Offshore Wind Energy in the United States From 2025 to 2050

This study presents estimates of the levelized cost of energy (LCOE) of offshore wind energy throughout major U.S. coastal regions between a time frame of 2025 - 2050. The LCOE modeling accounts for impacts of supply chain shocks, inflation, and rising interest rates on cost. Given the near-term uncertainty in these factors, we present three possible scenarios driven by how uncertainty in costs, technology, and deployment may evolve over time. The cost increases reported by industry in recent years will likely be felt over next several years, but we expect long-term cost reductions enabled by growing offshore wind deployment and industry learning. This study helps inform decision-makers about the potential role that offshore wind energy can play in future clean energy strategies.

17 WIND ENERGY↗

NASA NTRS2016

Additively Manufactured Low Cost Upper Stage Combustion Chamber

Over the past two years NASA's Low Cost Upper Stage Propulsion (LCUSP) project has developed Additive Manufacturing (AM) technologies and design tools aimed at reducing the costs and manufacturing time of regeneratively cooled rocket engine components. High pressure/high temperature combustion chambers and nozzles must be regeneratively cooled to survive their operating environment, causing their design fabrication to be costly and time consuming due to the number of individual steps and different processes required. Under LCUSP, AM technologies in Sintered Laser Melting (SLM) GRCop-84 and Electron Beam Freeform Fabrication (EBF3) Inconel 625 have been significantly advanced, allowing the team to successfully fabricate a 25k-class regenerative chamber. Estimates of the costs and schedule of future builds indicate cost reductions and significant schedule reductions will be enabled by this technology. Characterization of the microstructural and mechanical properties of the SLM-produced GRCop-84, EBF3 Inconel 625 and the interface layer between the two has been performed and indicates the properties will meet the design requirements. The LCUSP chamber is to be tested with a previously demonstrated SLM injector in order to advance the Technology Readiness Level (TRL) and demonstrate the capability of the application of these processes. NASA is advancing these technologies to reduce cost and schedule for future engine applications and commercial needs.

Protz, Christopher↗

DOE OSTI2025

Akiachak Energy Efficiency Retrofit Project

The goal of the project is to reduce the overall energy use of the Akiachak Native Community (ANC) by implementing energy efficiency measures in five high-use Tribal buildings. This project will have the following outcomes: Projected annual energy savings of $17,369; projected annual reduction in fuel oil #1 of 1,200 gallons and electricity of 17,751 kWh; annual reduction in carbon dioxide emissions of approximately 60,340 pounds/year. ANC will install energy efficiency measures in the Laundry, Tribal Indian Reorganization Act (IRA) Office, Clinic, Daycare, and Police Station. ANC obtained energy audits on these buildings in 2018, and this project will implement high-payback recommendations such as replacing lighting with LEDs, installing setback thermostats and occupancy sensors, replacing furnaces with more efficient models, replacing the circulation pumps with variable speed ones, air tightening, and adding insulation. Buildings will see energy cost reductions from 15% to 40%. These retrofits will help build ANC’s long-term vision for sustainable energy usage and address the first goal of the Tribal IRA Council’s Energy Efficiency and Conservation Strategy, to “create and maintain functionally appropriate, sustainable, accessible, high quality tribal infrastructure and facilities.” ANC intends to replicate this project by using the resulting energy savings to address audit recommendations in other buildings as well as to demonstrate the value of energy efficiency to community members. Other outcomes will include an increase in community resiliency, reduced dependence on outside shipments of fuel oil, training for maintenance staff, and no-touch control of building appliances to reduce transmission of diseases such as COVID-19.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

NASA NTRS1982

Space Shuttle/high energy upper stage capabilities for the 1990's

Possible performance gains and cost reductions available through the evolution of succeedingly larger unmanned, and then manned, orbital transfer vehicles (OTV) as Shuttle upper stages are projected. Future missions could include delivery of 10,000 lb to GEO, planetary missions in the 2000-12,000 lb class, 30-42 ft payloads in the 5000-10,000 lb class, and manned and unmanned satellite servicing by the turn of the century. The vehicles could evolve from the Centaur F vehicle through stages of all-propulsive configurations to aerobraked, fully reusable vehicles. Reusability introduces cost savings and the ability to make plane changes. Furthermore, aerobraking will double the payload capability for round trip journeys to GEO, bringing costs down to $7000/lb.

Teixeira, C.↗

NASA NTRS2010

Transport and Use of a Centaur Second Stage in Space

As nations continue to explore space, the desire to reduce costs will continue to grow. As a method of cost reduction, transporting and/or use of launch system components as integral components of missions may become more commonplace in the future. There have been numerous scenarios written for using launch vehicle components (primarily space shuttle used external tanks) as part of flight missions or future habitats. Future studies for possible uses of launch vehicle upper stages might include asteroid diverter using gravity orbital perturbation, orbiting station component, raw material at an outpost, and kinetic impactor. The LCROSS (Lunar CRater Observation and Sensing Satellite) mission was conceived as a low-cost means of determining whether water exists at the polar regions of the moon. Manifested as a secondary payload with the LRO (Lunar Reconnaissance Orbiter) spacecraft aboard an Atlas V launch vehicle, LCROSS guided its spent Centaur Earth Departure Upper Stage (EDUS) into the lunar crater Cabeu's, as a kinetic impactor. This paper describes some of the challenges that the LCROSS project encountered in planning, designing, launching with and carrying the Centaur upper stage to the moon.

Strong, James M.↗

NASA NTRSDate not supplied

Thermoplastic Aircraft Manufacturing Model

A manufacturing process to produce 80 single aisle sized thermoplastic composite aircraft a month is presented. Within the Hi-Rate Composite Aircraft Manufacturing (HiCAM) program a baseline aircraft fuselage was designed and modeled based on the Boeing 787 one-piece barrel build, but scaled down to a single aisle aircraft. Key Performance Parameters (KPPs) of recurring cost, non-recurring cost, and weight are calculated from the model. The outcome of this simulation indicated a prohibitively high non-recurring cost, so the thermoplastic team modeled the manufacturing flow for a panelized fuselage concept. The minimum success criteria is a 30% cost reduction and less than two percent increase in weight compared to the baseline aircraft. Automated Fiber Placement (AFP) is used to layup skins, stamp forming is used to make body frames, stringers, and passenger door surround parts. In the model, Co-Fusion was used to consolidate the skin while simultaneously welding on stringers to make stiffened panels. Additional welding technologies were considered to minimize fastener use and a vertical build concept was used for final assembly to reduce factory size. This manufacturing concept for a thermoplastic aircraft indicated a 39% cost and 12% weight savings compared to the baseline. Additional trade studies were conducted using Northrop Grumman’s Automated Stiffener Forming technology to make stringers and stamp forming instead of AFP to make skins.

thermoplastic composites↗

NASA NTRSDate not supplied

Thermoplastic Composite Aircraft Manufacturing Model

thermoplastic composites↗

NASA NTRS2010

Lunar Daylight Exploration

With 1 rover, 2 astronauts and 3 days, the Apollo 17 Mission covered over 30 km, setup 10 scientific experiments and returned 110 kg of samples. This is a lot of science in a short time and the inspiration for a barebones, return-to-the-Moon strategy called Daylight Exploration. The Daylight Exploration approach poses an answer to the question, What could the Apollo crew have done with more time and today s robotics? In contrast to more ambitious and expensive strategies that create outposts then rely on pressurized rovers to drive to the science sites, Daylight Exploration is a low-overhead approach conceived to land near the scientific site, conduct Apollo-like exploration then leave before the sun goes down. A key motivation behind Daylight Exploration is cost reduction, but it does not come at the expense of scientific exploration. As a goal, Daylight Exploration provides access to the top 10 science sites by using the best capabilities of human and robotic exploration. Most science sites are within an equatorial band of 26 degrees latitude and on the Moon, at the equator, the day is 14 Earth days long; even more important, the lunar night is 14 days long. Human missions are constrained to 12 days because the energy storage systems required to operate during the lunar night adds mass, complexity and cost. In addition, short missions are beneficial because they require fewer consumables, do not require an airlock, reduce radiation exposure, minimize the dwell-time for the ascent and orbiting propulsion systems and allow a low-mass, campout accommodations. Key to Daylight Exploration is the use of piloted rovers used as tele-operated science platforms. Rovers are launched before or with the crew, and continue to operate between crew visits analyzing and collecting samples during the lunar daylight

Griffin, Brand Norman↗

DOE OSTI2025

A Novel, Low-Cost, Portable Device for Counterfeit and Noncompliant Refrigerant Detection

The increasing prevalence of counterfeit refrigerants presents significant risks to Heating, Ventilation, Air Conditioning, and Refrigeration (HVACR) systems, including compromised equipment performance, safety hazards, and environmental non-compliance. This report details the development of a novel, cost-effective, and portable detection device designed to accurately identify counterfeit refrigerants. The device utilizes a controlled gas sampling and analysis system within a sealed chamber, ensuring precise measurements while maintaining safety through a purging mechanism. The system features a high-sensitivity sensor integrated with an onboard control module that analyzes gas composition in real-time, providing users with clear visual indicators for refrigerant authenticity.Laboratory validation demonstrated the device’s high accuracy (exceeding 95%) in detecting unauthorized refrigerant blends. Key advantages include affordability, ease of use, rapid response time, and compatibility with a wide range of refrigerants. This solution supports compliance with regulatory frameworks such as the American Innovation and Manufacturing (AIM) Act, enhances safety in HVACR operations, and mitigates the risks associated with counterfeit refrigerants. Future developments will focus on expanding refrigerant detection capabilities, integrating machine learning for enhanced accuracy, implementing cost-reduction strategies to improve accessibility and market adoption, and optimizing system packaging for enhanced field portability.

99 GENERAL AND MISCELLANEOUS↗

NASA NTRS1986

Orbital transfer vehicle concept definition and system analysis study. Volume 1A: Executive summary. Phase 2

The objectives of the Phase 2 study were to improve the orbit transfer vehicle (OTV) concept definition by focusing on the following issues: the impact of mission requirements on OTV system design; OTV basing concepts on the Space Shuttle, separate platforms, and/or remote locations; cost reduction of an OTV program to improve its economic benefits and support its acquisition. The OTV mission scenario includes a wide range of missions the main drivers of which are manned GEO servicing, mid-inclination/polar DOD, and lunar/planetary projects. A mission model is presented which includes the type and number of missions per year and the estimated propellant requirements. To accomplish the missions, many OTV concepts were defined including ground-based OTVs launched either in the STS orbiter, the aft cargo carrier, or a heavy lift launch vehicle, and a space-based OTV. System and program trade studies were conducted using performance, cost, safety/risk, and operations/growth criteria. The study shows that mission requirements and substantial economic benefits justify a reusable, cryogenic (H2/O2) space-based OTV. Such a system would not be subjected to Earth-to-orbit launch loads and would not be constained in size or weight. Safety is enhanced by the fact that the system components are launched unfueled. Its inherent reusability and ability to be refueled in space make the space-based OTV very economical to operate.

Ketchum, W. J.↗

DOE OSTI2024

An Evaluation of the Effect of Network Cost Optimization for Leadership Class Supercomputers

Dragonfly-based networks are an extensively deployed network topology in large-scale high-performance computing due to their cost-effectiveness and efficiency. The US will soon have three Exascale supercomputers for leadership class workloads deployed using dragonfly networks. Compared to indirect networks of similar scale, the dragonfly network has considerably reduced cable lengths, cable counts, and switch counts, resulting in significant network cost savings for a given system size, however, these cost reductions result in reduced global minimal paths and more challenging routing. Additionally, large scale dragonfly networks often require a taper at the global link level, resulting in less bisection bandwidth than is achievable in other traditional non-blocking topologies of equivalent scale. While dragonfly networks have been extensively studied, they have yet to be fully evaluated in an extreme scale (i.e., exascale) system that targets capability workloads. In this paper, we present the results of the first large scale evaluation of a dragonfly network on an exascale system (Frontier) and compare its behavior to a similar scale fat-tree network on a previous generation TOP500 system (Summit). This evaluation aims to determine the effect of network cost optimizations by measuring a tapered topology’s impact on capability workloads. Our evaluation is based on a collection of synthetic microbenchmarks, mini-apps, and full scale applications. It compares the scaling efficiencies of each benchmark between the dragonfly-based Frontier and the fat-tree-based Summit systems. Our results show that a dragonfly network is $\sim \mathbf{3 0 \%}$ more cost efficient than a fat-tree topology, which amortizes to $\sim 3 \%$ of an exascale system cost. Furthermore, while tapered dragonfly networks impose significant tradeoffs, the impacts are not as broad as initially thought and are mostly seen in applications with global communication patterns, particularly all-to-all (e.g., FFT-based algorithms), but also local communication patterns (e.g., nearest-neighbor algorithms) that are sensitive to network performance variability.

Khan, Awais↗

NASA NTRS2000

Novel Vibration Damping of Ceramic Matrix Composite Turbine Blades Developed for RLV Applications

The Reusable Launch Vehicle (RLV) represents the next generation of space transportation for the U.S. space program. The goal for this vehicle is to lower launch costs by an order of magnitude from $10,000/lb to $1,000/lb. Such a large cost reduction will require a highly efficient operation, which naturally will require highly efficient engines. The RS-2200 Linear Aerospike Engine is being considered as the main powerplant for the RLV. Strong, lightweight, temperature-resistant ceramic matrix composite (CMC) materials such as C/SiC are critical to the development of the RS-2200. Preliminary engine designs subject turbopump components to extremely high frequency dynamic excitation, and ceramic matrix composite materials are typically lightly damped, making them vulnerable to high-cycle fatigue. The combination of low damping and high-frequency excitation creates the need for enhanced damping. Thus, the goal of this project has been to develop well-damped C/SiC turbine components for use in the RLV. Foster-Miller and Boeing Rocketdyne have been using an innovative, low-cost process to develop light, strong, highly damped turbopump components for the RS-2200 under NASA s Small Business Innovation Research (SBIR) program. The NASA Glenn Research Center at Lewis Field is managing this work. The process combines three-dimensionally braided fiber reinforcement with a pre-ceramic polymer. The three-dimensional reinforcement significantly improves the structure over conventional two-dimensional laminates, including high through-the-thickness strength and stiffness. Phase I of the project successfully applied the Foster-Miller pre-ceramic polymer infiltration and pyrolysis (PIP) process to the manufacture of dynamic specimens representative of engine components. An important aspect of the program has been the development of the manufacturing process. Results show that the three-dimensionally braided carbon-fiber reinforcement provides good processability and good mechanical stiffness and strength in comparison to materials produced with competing processes as shown in the graphs.

Min, James B.↗

DOE OSTI2024

Scale effects on core design, fuel costs, and spent fuel volume of pressurized water reactors

The desire to improve the economic competitiveness and deployment pace of nuclear energy through modularization, manufacturing, and series production had led to the development of smaller size reactors. As the standard 17x17 fuel technology is mainly maintained in the pressurized water reactors (PWRs) category, this translates into a lower number of fuel assemblies in the core and sometimes a reduced fuel height. To assess the impact of such scale change in core design on fuel cycle cost and spent fuel volume, a scoping analysis tool is developed based on infinite lattice calculations, leakage, fuel management reduced models, and levelized unit cost of electricity (LCOE) estimate. As such, cost dynamics driven by fuel specific power, burnup, core leakage, feed, cycle length, fuel assembly height as well as uranium market data are captured with consistent set of assumptions and analysis methods. A selection of 5 reactor designs representative of leading PWR developers is assessed and compared. Pursuing higher specific powers and optimal burnups are highlighted as the main fuel cost reduction drivers, nevertheless, practical limitations and opportunities must be evaluated to establish the feasibility of such enhanced fuel operation. In consequence, a detailed core design is performed using SIMULATE3 code for 5 PWR variations including natural and forced coolant circulation modes, two reactor scales, power densities of 73, 112, and 123 kW/l and higher discharge burnups. Design and optimization are performed at the lattice level, for the reflector, and at the core loading level. Satisfactory steady-state operation including power distribution, coolant operating limits, and reactivity requirements are analyzed and reported in this paper. The fuel economics of the detailed core designs confirm the scoping analysis findings. Despite the unlocked power uprates in small PWRs, the achievable burnup for a given fuel specific power requires more enrichment and shorter fuel height results in higher fabrication costs per mass of fuel, which makes scaling down core size a more expensive endeavor on the fuel cycle front. Spent fuel volumes are reported for the PWRs designed in this paper. Furthermore, these volumes are driven by the core average discharge burnup regardless of the scale in consideration. Additional cost and core performance aspects related to heavy reflector gains, fuel-reflector substitution, and disposal cost policy in the U.S. are examined.

42 ENGINEERING↗

DOE OSTI2025

Fuel cells for single-aisle regional aircraft: System configuration, performance and cost

A hydrogen fuel cell propelled electric aircraft can compete with incumbent turbofan technologies for single-aisle regional aircraft by coupling design of stack, air handling, thermal management, propulsion, and airframe to optimize performance. The stack operates at 95°C to facilitate heat rejection during take-off and below 75°C during cruise to extend lifetime and is oversized to satisfy power requirements at end of life. A multi-stage turbocompressor with a compression ratio >10 is selected to reach high stack power density at 11,300-m cruise altitude. The propulsion system is configured to accommodate air handling within the core duct, an inclined heat exchanger in the outer duct to limit the nacelle size, and variable area nozzles to independently control mass flows through the core and bypass ducts. The airframe is modified for maximum lift coefficient and longer balanced field length for dramatically reduced thrust during take-off, and the fuselage is stretched by 20% to store liquid hydrogen (LH 2 ). Modularization of power systems promotes safety in one engine inoperative scenarios and allows reaching specific power metrics for stack, balance-of-plant and fuel cell system (FCS), necessary for acceptable take-off weight. In conclusion, cost parity requires increase in FCS lifetime, LH 2 cost reduction, and improved FCS specific power.

Catalyst durability↗

DOE OSTI2024

Contactless Production Testing of Silicon Solar Cells

Critical cost reductions in silicon solar cells are made by minimizing silver usage in their metal contacts. The reason why is both clear and unavoidable—silver is not only expensive, but also a potential limiting resource for scale-up (the PV industry alone used 10.3 % of the global silver supply in 2020 [1]). The result is solar cells with vanishing electrical contact area that are extremely difficult to test prior to module manufacture, when they must be sorted for quality to maximize power output and reliability of the subsequent modules. This project developed a new measurement instrument that enables the transition to solar cells with very low silver content, including cell designs with both minimal busbars and no busbars at all to electrically contact. The resulting instrument at project completion demonstrated the ability to sort cells with comparable—or better—results than existing technology. Compared to existing cell-test instruments, the new tool has minimal contacting requirements, which lowers the maintenance costs and use of consumable parts. We demonstrated innovative, yet pragmatic, solutions for reporting a comprehensive set of measurement results useful for both cell sorting (going forward in the line for module manufacture) and process control (looking backward in the line to identify cell manufacturing issues from wafer to cell-test). In addition to the traditional current-voltage characterization at cell test—short circuit current, open-circuit voltage, power, efficiency and fill factor—the new tool maintains all the advanced parameter characterization of our existing product line such as a substrate doping measurement, carrier recombination (lifetime) analysis, and surface recombination analysis.

14 SOLAR ENERGY↗