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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.

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338 records · Page 2
All sourcesNASA NTRSDOE OSTI
NASA NTRS2026

Manufacturing Process Development of a Carbon Fiber Reinforced Polymer Composite Shaft for Electric Motors

Electric aircraft applications require electric motors with increased specific power and efficiency. Composite structural components in motors are a potential solution for reducing motor mass, reducing magnetic losses, and limiting undesired conduction paths for fault, electromagnetic interference, or common-mode currents. In this report, manufacturing trials for a high-speed carbon fiber reinforced polymer composite motor shaft are presented. Four prototype shafts were produced using a hybrid biaxial/triaxial fabric that was circumferentially wrapped onto an additively manufactured high-temperature washout mandrel. An additional traditional overbraid approach was also evaluated and shows promise for high-rate, high-performance parts using automated manufacturing. This paper discusses the shaft design, manufacturing methods explored, material selection, the manufacturing trials, and the lessons learned. The results of this manufacturing investigation show feasibility for manufacturing composite shafts for electric motors.

Electric moto shaft↗
NASA NTRS2026

NASA Weather Balloon Demonstration of an Additively Manufactured Antenna

Additive manufacturing (AM) enables low-cost, lightweight, and geometrically flexible antennas for rapid deployment missions. This work reports a left-hand circularly polarized magneto-electric dipole printed on a Radix dielectric with inkjet silver metallization and demonstrated as a process replacement for NASA weather-balloon RF hardware. By combining substrate fabrication and metallization, AM provides value for unrecoverable or field-replaceable systems. A physics based verification workflow links AM-specific material behavior to electromagnetic performance and yields bounded total, radiation, and mismatch efficiencies. Standard surface-impedance and roughness models failed to reproduce the frequency-dependent radiation loss observed in printed inks, underscoring the need for AM-specific conductor parameterization. Mission testing confirmed TDRSS link closure from NASA’s Columbia Scientific Balloon Facility and validated a repeatable print–measure–fly workflow for bounding RF performance and qualifying AM antennas for field use.

Peter Moschetti↗
NASA NTRSDate not supplied

NASA Weather Balloon Demonstration of an Additively Manufactured Antenna

Additive manufacturing (AM) enables low-cost, lightweight, and geometrically flexible antennas for rapid deployment missions. This work reports a left-hand circularly polarized magneto-electric dipole printed on a Radix dielectric with inkjet silver metallization and demonstrated as a process replacement for NASA weather-balloon RF hardware. By combining substrate fabrication and metallization, AM provides value for unrecoverable or field-replaceable systems. A physics based verification workflow links AM-specific material behavior to electromagnetic performance and yields bounded total, radiation, and mismatch efficiencies. Standard surface-impedance and roughness models failed to reproduce the frequency-dependent radiation loss observed in printed inks, underscoring the need for AM-specific conductor parameterization. Mission testing confirmed TDRSS link closure from NASA’s Columbia Scientific Balloon Facility and validated a repeatable print–measure–fly workflow for bounding RF performance and qualifying AM antennas for field use.

Peter Moschetti↗
NASA NTRS2026

Computational Materials for Qualification and Certification (CM4QC) Strategy Document: Maturation of Computational Materials Methods for Aviation-Focused Qualification and Certification of Metal Additive Manufacturing (as an Example of Process-Intensive Materials)

Although considerable scientific and technological advances have been made in recent years in additive manufacturing (AM) processes, these advances have not translated into significant market penetration of AM parts within the aviation industry. It is broadly acknowledged that using traditional qualification and certification (Q&C) approaches for AM components is one of the most significant barriers to broader adoption of AM, resulting in high costs, long product development and certification timelines, and complex design iterations during the product development cycle. A new approach is urgently needed. This document lays out a vision for a new Q&C paradigm with increased use of computational materials (CM) methods aimed at decreasing the time and cost of Q&C of process-intensive material (PIM) approaches in the aviation industry, with AM as the immediate use case. This vision was developed with substantial input from industry, regulatory agencies, government research organizations, and academia.

Edward H Glaessgen↗
NASA NTRSDate not supplied

Evaluating Crystallinity in Thermoplastic composites

Polymer matrix composites (PMCs) offer many benefits for the aerospace industry due to their potential for weight reduction when compared to metal or ceramic based materials. Most PMCs currently in flight use thermoset matrices, however, thermoplastic resins are being explored as alternatives due to their ability to be remelted, which is of particular interest due to the potential for in-situ repair and manufacturing required in space. Most thermoplastic resins are semicrystalline polymers. The properties of semicrystalline thermoplastics are largely influenced by their crystallinity, which can vary due to many factors including thermal treatments, environmental conditions, and mechanical deformation. Monitoring the crystallinity of thermoplastic composites is key to ensuring these materials reliably meet the high demands required by space exploration. This talk discusses the use of multiple techniques such as Polarized Light Optical Microscopy and Fourier-Transform Infrared Spectroscopy to characterize the crystallinity in various thermoplastic composites, including carbon fiber reinforced PMCs and novel bio-based Martian and Lunar regolith composites designed for in-situ manufacturing. This work aims to provide the fundamental data necessary to understand the effects of crystallinity on thermoplastic PMCs, which is key to advancing their use in space applications.

Thermoplastics↗
NASA NTRS1997

The Effect of Gravity on the Combustion Synthesis of Porous Ceramics and Metal Matrix Composites

Combustion synthesis (self propagating, high temperature synthesis-SHS) is a novel technique that is capable of producing many advanced materials. The ignition temperature (Tig) of such combustion synthesis reactions is often coincident with that of the lowest melting point reactant. The resultant liquid metal wets and spreads around the other solid reactant particles of higher melting points, thereby improving the reactant contact and kinetics, followed by formation of the required compounds. This ignition initiates a combustion propagating wave whose narrow reaction front rapidly travels through the reactants. Since this process is highly exothermic, the heat released by combustion often melts the reactant particles ahead of the combustion front and ignites the adjacent reactant layer, resulting in a self-sustaining reaction. Whenever a fluid phase (liquid or gas) is generated by the reaction system, gravity-driven phenomena can occur. Such phenomena include convective flows of fluid by conventional or unstable convection and settling of the higher density phases. A combustion process is often associated with various kinds of fluid flow. For instance, if the SHS reaction is carried out under inert or reactive gas atmospheres, or a volatile, e.g., B2O3, is deliberately introduced as a reactant, convective flows of the gas will occur due to a temperature gradient existing in the atmosphere when a combustion wave is initiated. The increased gas flow will produce a porous (or expanded) SHS product. Owing to the highly exothermic nature of many SHS reactions, liquid phase(s) can also form before, at, or after the combustion front. The huge temperature gradient at the combustion front can induce convective flows (conventional or unstable) of the liquid phase. Each of these types of convective fluid flow can change the combustion behavior of the synthesizing reaction, and, therefore, the resultant product microstructure. In addition, when two or more phases of different density are produced at or ahead of the propagating combustion front settling of the higher density phase will occur resulting in a non-uniform product microstructure and properties.

J J Moore↗
NASA NTRSDate not supplied

Mitigating Grazing Flow Impedance Eduction Errors in Additively Manufactured Porous Liners

Additively manufactured porous metamaterials, including triply periodic minimal surface (TPMS) cores, are promising candidates for aeroengine liners but often behave as extended-reacting treatments under grazing flow. Standard impedance eduction procedures assume locally-reacting behavior and can yield physically inconsistent results for such materials. This study evaluates internal partitions (thin solid walls inserted at regular intervals along the liner’s streamwise extent) as a means of suppressing internal streamwise propagation to improve eduction consistency. Six TPMS configurations were tested in the NASA Langley Grazing Flow Impedance Tube (GFIT) at partition spacings of 4′′, 2′′, and 1′′, as well as unpartitioned, and at Mach numbers up to 0.3. For most geometries, 2′′ partition spacing eliminated impedance discontinuities and substantially improved Prony correlation, though effectiveness varied with core topology. Partitions also altered the acoustic response of the liners: resistance increased, resonance frequencies shifted downward, and peak attenuation decreased while bandwidth broadened in some cases. Because partitions modify the liner itself, the educed impedance characterizes the partitioned system rather than the original unpartitioned core. These results establish partitioning as a practical pathway toward liners that are more compatible with standard eduction methods, while demonstrating that the intervention is itself an acoustic design change.

liners↗
NASA NTRSDate not supplied

A Frank Discussion on Lessons Learned From Adopting and Applying NASA-STD-6030 for Spaceflight Systems

With the advancement and adoption of Additive Manufacturing (AM) for spaceflight systems, numerous lessons have been learned during the qualification and certification of AM components. The lessons learned covered in this presentation will provide an overview of the challenges faced by NASA centers and commercial partners working to design AM hardware that complies with NASA-STD-6030 Additive Manufacturing Requirements (AMR). Topics of interest include tailoring of requirements for specific projects, documentation requirements, and addressing conservative approaches towards mechanical property development and analysis. In addition to that, this presentation aims to impress that these lessons learned will influence the future revisions of the NASA technical standard to facilitate and advance AM technology adoption on NASA projects.

Additive Manufacturing↗
NASA NTRS2026

Extrusion-based Additive Manufacturing of Regolith-Filled Shape Memory Vitrimer Composite for Lunar Construction

The National Aeronautics and Space Administration (NASA) is visiting the moon again. This time, the objective is to explore establishing a permanent lunar base. To achieve both longterm human habitation on the moon and future deep space travel, it is crucial to make the most of the in-situ resources and build autonomous systems on the moon to support the construction of a lunar habitat. NASA’s In-situ Resource Utilization (ISRU) program aims to minimize the need to ship heavy prefabricated structures, reducing cost and enhancing sustainability. Here, we developed an economical extrusion method for printing lunar regolith-based composites using shape memory vitrimer as a binder. A rheological study is conducted to determine the extrudability of the composite with different regolith weight percentages. Several characterizations were conducted on the composites. The as-printed composites exhibited compressive and flexural strengths of 73.32 MPa and 156.59 MPa, respectively, and good impact tolerance. The composite maintained 57.92% of its mechanical properties even after the second crack healing cycle. The composites also exhibit shape fixity ratio of 90.02% and shape recovery ratio of 83.46%. The simple synthesis method, sustainability, and good thermomechanical properties make the 3D printed composite an ideal material for lunar construction applications.

Kingsley Yeboah Gyabaah↗
NASA NTRSDate not supplied

Development of an Additively Manufactured Subscale Secondary Sealed Container for the NASA FROSTE Project

This presentation details the development of an additively manufactured (AM) subscale test article for the secondary sealed container (SSC) as part of the NASA FROSTE project. FROSTE is focused on the collection of regolith samples from shadowed regions of the Moon and the preservation of those samples at cryogenic temperatures for return to Earth. Our team was integrated into the FROSTE program to leverage innovative design approaches and additive manufacturing capabilities in support of a scalable development strategy, where the subscale configuration serves as the development path toward a full-scale SSC. Scalmalloy was selected as the primary material for all AM components due to its favorable strength-to-weight ratio, thermal conductivity, and demonstrated performance in aerospace applications. Its aluminum-based composition supports robust mechanical behavior at cryogenic temperatures while enabling efficient heat transfer and control of thermal gradients within the containment system. The SSC architecture consists of an outer container assembly that houses a phase change material (PCM) tank, which in turn contains primary containers holding the regolith. Thermal management relies on controlled conductive and radiative heat transfer, including a thermal connection assembly that interfaces the PCM tank to an external cryocooler via a thermal strap, and IMLI surrounding the PCM tank to inhibit radiative heat transfer. The outer container assembly incorporates sealing interfaces, thermal connection ports, and I/O feedthroughs, with PTFE spring seals used at critical interfaces to maintain containment integrity. The PCM tank is manufactured as a single monolithic Scalmalloy component and incorporates an integral lattice structure to minimize thermal gradients, internal channels for thermocouple routing, and interface features for thermal connection assembly integration. The tank is centrally suspended within the outer container using support rings, with G10 insulating components employed to inhibit thermal leaks. This work describes the design methodology, AM approach, and key considerations used to inform the design.

regolith↗
NASA NTRS2026

Ceramics at Hypersonic Limits

This presentation outlines the regimes of hypersonic flight and the application of ceramic materials.

hypersonic flight↗
NASA NTRS2026

Electromagnetic Melt Processing: A Pathway to New Additive Manufacturing Technologies for Functional High-Performance Thermoplastics

In this study, we apply the electromagnetic (EM) melt processing of thermoplastics on an innovative EM field-driven powder bed fusion additive manufacturing (AM) concept for high-performance functional parts: Selective Microwave Melting/Sintering (SMM/SMS). This technique leverages the EM susceptibility of carbon nanotube-coated polymer micro-pellets to achieve rapid, localized heating and powder fusion. Thus, selective microwave melting (SMM) was used to fabricate multilayer specimens made of recycled polyphenylene sulfide (rPPS) and carbon nanotubes (CNTs). The resulting SMM specimens exhibited very good interlayer integrity, localized fusion at pellet boundaries, and tolerable residual porosity, indicating effective fusion and acceptable consolidation. CNT-rich interphases were retained after irradiation, generating anisotropic electrically active network pathways and enabling conductivity enhancement at low filler content. At only 1.0 wt% CNT, the specimens exhibited electrical conductivity approximately three orders of magnitude higher than neat rPPS. Dynamic mechanical analysis showed improved viscoelastic response relative to neat rPPS, while tensile testing confirmed that the SMM-processed specimens retained practical mechanical integrity despite localized voids. These results demonstrate that SMM can effectively consolidate EM susceptible thermoplastic powder beds while preserving their segregated conductive networks. This may become a scalable route for producing multifunctional thermoplastic parts with low filler loadings, tunable anisotropy, and structured materials and parts. Overall, the findings suggest that EM field-based AM can help overcome key limitations of conventional thermoplastic processing by enabling scalable, energy-efficient fabrication of nanostructured composites and expanding AM to a broader range of resins, including high-performance thermoplastics with customized functional properties.

Powder bed fusion↗