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Rapid Assessment of a Lunar Surface Laboratory Module

Johnson Space Center has piloted an innovation team known as the Forge to perform rapid turnaround, concurrent engineering studies. The Forge is intended to be able to pull together a team of strategically selected domain experts to innovatively solve a specified problem within a short period of time. The Forge’s inaugural project was the development of a Lunar Surface Laboratory Module concept. The lab module is intended as an option for the NASA Lunar Architecture Team and may allow for increased science productivity and return on investment than with only the Surface Habitat. The Forge team developed two concepts, a stationary laboratory and a mobile laboratory. Human factors evaluations have been conducted to determine the acceptability of the resulting design concepts. The human factors evaluations conducted include a card sort evaluation of the laboratories by science discipline and the System Usability Scale (SUS). The card sort is focused subject matter expert expectations for the relative positioning of the laboratory functional areas, determining whether a given lab area should be adjacent to, or separated from, another. The SUS will focus on layout efficiency. Both will use human factors personnel and both life and physical scientists as subject matter experts. Each of these evaluations will focus primarily on objective data with limited subjective comments, reducing the time required for processing responses. The results of the card sort and SUS evaluations and their implications will be discussed. Based on the evaluation data, an overall acceptability of the Lunar Surface Laboratory Module produced by the Forge study can be determined. Lessons learned and recommendations for future use of human factors rapid assessment processes in early design trades will also be provided.

Human Factors↗

NASA NTRS2006

A Core Plug and Play Architecture for Reusable Flight Software Systems

The Flight Software Branch, at Goddard Space Flight Center (GSFC), has been working on a run-time approach to facilitate a formal software reuse process. The reuse process is designed to enable rapid development and integration of high-quality software systems and to more accurately predict development costs and schedule. Previous reuse practices have been somewhat successful when the same teams are moved from project to project. But this typically requires taking the software system in an all-or-nothing approach where useful components cannot be easily extracted from the whole. As a result, the system is less flexible and scalable with limited applicability to new projects. This paper will focus on the rationale behind, and implementation of the run-time executive. This executive is the core for the component-based flight software commonality and reuse process adopted at Goddard.

Wilmot, Jonathan↗

DOE OSTI2026

Hydrodynamic Modelling for Tidal Energy Kites: Cooperative Research and Development Final Report, CRADA Number CRD-24-30123

The primary goal of the work is to improve accuracy of hydrodynamic loads acting on the lifting surface of the kite turbine due to complex air-water-lifting body interaction in a low-order numerical model using high-fidelity numerical input. The result of this study will help the Participant better design control algorithms for the kite turbine so that the turbine can harvest more energy while maintaining stability of the platform as well as its reliability. The use of hydrodynamic coefficients/load components from computational fluid dynamic simulation will inform better inputs for a medium-fidelity dynamic model (specifically an OrcaFlex model) which is intended for use in rapid design iterations in the design process.

16 TIDAL AND WAVE POWER↗

NASA NTRS1987

Computer architecture for efficient algorithmic executions in real-time systems: New technology for avionics systems and advanced space vehicles

Improvements and advances in the development of computer architecture now provide innovative technology for the recasting of traditional sequential solutions into high-performance, low-cost, parallel system to increase system performance. Research conducted in development of specialized computer architecture for the algorithmic execution of an avionics system, guidance and control problem in real time is described. A comprehensive treatment of both the hardware and software structures of a customized computer which performs real-time computation of guidance commands with updated estimates of target motion and time-to-go is presented. An optimal, real-time allocation algorithm was developed which maps the algorithmic tasks onto the processing elements. This allocation is based on the critical path analysis. The final stage is the design and development of the hardware structures suitable for the efficient execution of the allocated task graph. The processing element is designed for rapid execution of the allocated tasks. Fault tolerance is a key feature of the overall architecture. Parallel numerical integration techniques, tasks definitions, and allocation algorithms are discussed. The parallel implementation is analytically verified and the experimental results are presented. The design of the data-driven computer architecture, customized for the execution of the particular algorithm, is discussed.

Carroll, Chester C.↗

NASA NTRS2011

Range 7 Scanner Integration with PaR Robot Scanning System

An interface bracket and coordinate transformation matrices were designed to allow the Range 7 scanner to be mounted on the PaR Robot detector arm for scanning the heat shield or other object placed in the test cell. A process was designed for using Rapid Form XOR to stitch data from multiple scans together to provide an accurate 3D model of the object scanned. An accurate model was required for the design and verification of an existing heat shield. The large physical size and complex shape of the heat shield does not allow for direct measurement of certain features in relation to other features. Any imaging devices capable of imaging the entire heat shield in its entirety suffers a reduced resolution and cannot image sections that are blocked from view. Prior methods involved tools such as commercial measurement arms, taking images with cameras, then performing manual measurements. These prior methods were tedious and could not provide a 3D model of the object being scanned, and were typically limited to a few tens of measurement points at prominent locations. Integration of the scanner with the robot allows for large complex objects to be scanned at high resolution, and for 3D Computer Aided Design (CAD) models to be generated for verification of items to the original design, and to generate models of previously undocumented items. The main components are the mounting bracket for the scanner to the robot and the coordinate transformation matrices used for stitching the scanner data into a 3D model. The steps involve mounting the interface bracket to the robot's detector arm, mounting the scanner to the bracket, and then scanning sections of the object and recording the location of the tool tip (in this case the center of the scanner's focal point). A novel feature is the ability to stitch images together by coordinates instead of requiring each scan data set to have overlapping identifiable features. This setup allows models of complex objects to be developed even if the object is large and featureless, or has sections that don't have visibility to other parts of the object for use as a reference. In addition, millions of points can be used for creation of an accurate model [i.e. within 0.03 in. (=0.8 mm) over a span of 250 in. (=635 mm)].

Schuler, Jason↗

NASA NTRS2013

Small Projects Rapid Integration and Test Environment (SPRITE): Application for Increasing Robustness

Marshall Space Flight Center's (MSFC) Small Projects Rapid Integration and Test Environment (SPRITE) is a Hardware-In-The-Loop (HWIL) facility that provides rapid development, integration, and testing capabilities for small projects (CubeSats, payloads, spacecraft, and launch vehicles). This facility environment focuses on efficient processes and modular design to support rapid prototyping, integration, testing and verification of small projects at an affordable cost, especially compared to larger type HWIL facilities. SPRITE (Figure 1) consists of a "core" capability or "plant" simulation platform utilizing a graphical programming environment capable of being rapidly re-configured for any potential test article's space environments, as well as a standard set of interfaces (i.e. Mil-Std 1553, Serial, Analog, Digital, etc.). SPRITE also allows this level of interface testing of components and subsystems very early in a program, thereby reducing program risk.

Rakoczy, John↗

NASA NTRS1997

Verification and Validation in a Rapid Software Development Process

The high cost of software production is driving development organizations to adopt more automated design and analysis methods such as rapid prototyping, computer-aided software engineering (CASE) tools, and high-level code generators. Even developers of safety-critical software system have adopted many of these new methods while striving to achieve high levels Of quality and reliability. While these new methods may enhance productivity and quality in many cases, we examine some of the risks involved in the use of new methods in safety-critical contexts. We examine a case study involving the use of a CASE tool that automatically generates code from high-level system designs. We show that while high-level testing on the system structure is highly desirable, significant risks exist in the automatically generated code and in re-validating releases of the generated code after subsequent design changes. We identify these risks and suggest process improvements that retain the advantages of rapid, automated development methods within the quality and reliability contexts of safety-critical projects.

Callahan, John R.↗

DOE OSTI2026

Chemical and Radiological Compatibility Testing of 3D Printed Materials

To dramatically increase the adaptability, performance, and safety of processes in support of the Defense Waste Processing Facility (DWPF), Savannah River National Lab (SRNL) plans to perform chemical and radiological compatibility testing on a wide variety of 3D printed materials of interest. The 3D printing process provides numerous strategic operational benefits such as rapid prototyping of complex designs and geometry specific to the needs of the nuclear waste disposition process, as well as on-demand rapid prototyping and iteration with materials that aren’t as accessible through traditional manufacturing methods. Reaction chemistry in simulated waste batches can be matched closely to its radioactive counterpart, but glass reactor vessels have limitations. Vessel geometry can play a big factor in mixing transport limitations, process chemistry, and degradation reaction kinetics. In addition, additive manufacturing allows for much more detailed vessel design than traditional alternatives. Waste processing techniques in DWPF also encounter extreme chemical environments including high pH, strong acids, abrasive slurries, and significant irradiation. To meet these challenges, a matrix of various polymer, ceramic, and metal additive manufacturing materials have been exposed to a suite of chemical environments of interest as well as radioactive dose (such as gamma radiation from 60 Co) to properly test their durability under these conditions. Mass change has been monitored over a period of up to a week in these conditions, as well as added characterization for surface modification through Scanning Electron Microscopy/Electron Dispersive X-ray analysis (SEM/EDX). Further chemical characterization has been monitored through Fourier-Transform InfraRed Spectroscopy (FTIR), with planned investigation via thermal and tensile strength degradation. While the direct product of this research is identification of material(s) that can withstand specific hazardous environments encountered by the mercury water wash tank in DWPF process simulation experiments, the reference base of materials will be used for many other nuclear processes in the pursuit of rapidly developed, cost-efficient, and highly specific devices for environmental remediation and much more.

Wilson, Nathan W. [Savannah River National Laborat↗

DOE OSTI2024

Advanced Design and 3D Printing Strategies With Alginate‐Nanoclay Nanocomposites: From Microstructure to Bioprinting

Nanocomposites made from alginate and nanoclay are extensively applied for diverse biomedical applications. However, the lack of a clear understanding of the interactions between alginate and nanoclay makes it difficult to rationally design the nanocomposites for different material extrusion-based 3D bioprinting strategies. Here, a combined analytical model is proposed to accurately predict the interaction mechanisms between alginate and nanoclay through small-angle neutron scattering. These mechanisms are summarized into a phase diagram that can guide the design of alginate-nanoclay nanocomposites for different bioprinting applications. The rheological properties of various nanocomposites are measured to validate the proposed interaction mechanisms at the macroscale. Accordingly, three representative extrusion-based bioprinting strategies are linked with the nanocomposite design and applied to freeform fabricate complex structures. In conclusion, a roadmap is summarized to bridge the gap between biomaterial design and bioprinting processes, enabling the rapid and rational selection of biomaterial formula based on available 3D printing methods, and vice versa.

36 MATERIALS SCIENCE↗

NASA NTRS1993

Appendix B: Rapid development approaches for system engineering and design

Conventional processes often produce systems which are obsolete before they are fielded. This paper explores some of the reasons for this, and provides a vision of how we can do better. This vision is based on our explorations in improved processes and system/software engineering tools.

Source record↗

NASA NTRS2001

Multifunctional Collaborative Modeling and Analysis Methods in Engineering Science

Engineers are challenged to produce better designs in less time and for less cost. Hence, to investigate novel and revolutionary design concepts, accurate, high-fidelity results must be assimilated rapidly into the design, analysis, and simulation process. This assimilation should consider diverse mathematical modeling and multi-discipline interactions necessitated by concepts exploiting advanced materials and structures. Integrated high-fidelity methods with diverse engineering applications provide the enabling technologies to assimilate these high-fidelity, multi-disciplinary results rapidly at an early stage in the design. These integrated methods must be multifunctional, collaborative, and applicable to the general field of engineering science and mechanics. Multifunctional methodologies and analysis procedures are formulated for interfacing diverse subdomain idealizations including multi-fidelity modeling methods and multi-discipline analysis methods. These methods, based on the method of weighted residuals, ensure accurate compatibility of primary and secondary variables across the subdomain interfaces. Methods are developed using diverse mathematical modeling (i.e., finite difference and finite element methods) and multi-fidelity modeling among the subdomains. Several benchmark scalar-field and vector-field problems in engineering science are presented with extensions to multidisciplinary problems. Results for all problems presented are in overall good agreement with the exact analytical solution or the reference numerical solution. Based on the results, the integrated modeling approach using the finite element method for multi-fidelity discretization among the subdomains is identified as most robust. The multiple-method approach is advantageous when interfacing diverse disciplines in which each of the method's strengths are utilized. The multifunctional methodology presented provides an effective mechanism by which domains with diverse idealizations are interfaced. This capability rapidly provides the high-fidelity results needed in the early design phase. Moreover, the capability is applicable to the general field of engineering science and mechanics. Hence, it provides a collaborative capability that accounts for interactions among engineering analysis methods.

Ransom, Jonathan B.↗

NASA NTRS2014

Potential for Integrating Entry Guidance into the Multi-Disciplinary Entry Vehicle Optimization Environment

The state-of-the-art in vehicle design decouples flight feasible trajectory generation from the optimization process of an entry spacecraft shape. The disadvantage to this decoupled process is seen when a particular aeroshell does not meet in-flight requirements when integrated into Guidance, Navigation, and Control simulations. It is postulated that the integration of a guidance algorithm into the design process will provide a real-time, rapid trajectory generation technique to enhance the robustness of vehicle design solutions. The potential benefit of this integration is a reduction in design cycles (possible cost savings) and increased accuracy in the aerothermal environment (possible mass savings). This work examines two aspects: 1) the performance of a reference tracking guidance algorithm for five different geometries with the same reference trajectory and 2) the potential of mass savings from improved aerothermal predictions. An Apollo Derived Guidance (ADG) algorithm is used in this study. The baseline geometry and five test case geometries were flown using the same baseline trajectory. The guided trajectory results are compared to separate trajectories determined in a vehicle optimization study conducted for NASA's Mars Entry, Descent, and Landing System Analysis. This study revealed several aspects regarding the potential gains and required developments for integrating a guidance algorithm into the vehicle optimization environment. First, the generation of flight feasible trajectories is only as good as the robustness of the guidance algorithm. The set of dispersed geometries modelled aerodynamic dispersions that ranged from +/-1% to +/-17% and a single extreme case was modelled where the aerodynamics were approximately 80% less than the baseline geometry. The ADG, as expected, was able to guide the vehicle into the aeroshell separation box at the target location for dispersions up to 17%, but failed for the 80% dispersion cases. Finally, the results revealed that including flight feasible trajectories for a set of dispersed geometries has the potential to save mass up to 430 kg.

spacecraft guidance↗

NASA NTRS1992

Structures technology applications for the National AeroSpace Plane

The National AeroSpace Plane (NASP) presents a unique set of very complex structural problems that challenge our computational capabilities. Complex analyses are required in the conceptual design phase to achieve sufficient accuracy to address the extreme load conditions and to adequately evaluate vehicle weight. The computational capability must be available to perform these analyses in a rapid manner to accommodate the design process.

Little, T. E.↗

NASA NTRS2011

X-33 Reusable Launch Vehicle Demonstrator, Spaceport and Range

The X-33 was a suborbital reusable spaceplane demonstrator, in development from 1996 to early 2001. The intent of the demonstrator was to lower the risk of building and operating a full-scale reusable vehicle fleet. Reusable spaceplanes offered the potential to lower the cost of access to space by an order of magnitude, compared with conventional expendable launch vehicles. Although a cryogenic tank failure during testing ultimately led to the end of the effort, the X-33 team celebrated many successes during the development. This paper summarizes some of the accomplishments and milestones of this X-vehicle program, from the perspective of an engineer who was a member of the team throughout the development. X-33 Program accomplishments include rapid, flight hardware design, subsystem testing and fabrication, aerospike engine development and testing, Flight Operations Center and Operations Control Center ground systems design and construction, rapid Environmental Impact Statement NEPA process approval, Range development and flight plan approval for test flights, and full-scale system concept design and refinement. Lessons from the X-33 Program may have potential application to new RLV and other aerospace systems being developed a decade later.

Letchworth, Gary F.↗

NASA NTRS2005

Enhancing the Design Process for Complex Space Systems through Early Integration of Risk and Variable-Fidelity Modeling

An important enabler of the new national Vision for Space Exploration is the ability to rapidly and efficiently develop optimized concepts for the manifold future space missions that this effort calls for. The design of such complex systems requires a tight integration of all the engineering disciplines involved, in an environment that fosters interaction and collaboration. The research performed under this grant explored areas where the space systems design process can be enhanced: by integrating risk models into the early stages of the design process, and by including rapid-turnaround variable-fidelity tools for key disciplines. Enabling early assessment of mission risk will allow designers to perform trades between risk and design performance during the initial design space exploration. Entry into planetary atmospheres will require an increased emphasis of the critical disciplines of aero- and thermodynamics. This necessitates the pulling forward of EDL disciplinary expertise into the early stage of the design process. Radiation can have a large potential impact on overall mission designs, in particular for the planned nuclear-powered robotic missions under Project Prometheus and for long-duration manned missions to the Moon, Mars and beyond under Project Constellation. This requires that radiation and associated risk and hazards be assessed and mitigated at the earliest stages of the design process. Hence, RPS is another discipline needed to enhance the engineering competencies of conceptual design teams. Researchers collaborated closely with NASA experts in those disciplines, and in overall space systems design, at Langley Research Center and at the Jet Propulsion Laboratory. This report documents the results of this initial effort.

Mavris, Dimitri↗

NASA NTRS2007

ESAS-Derived Earth Departure Stage Design for Human Mars Exploration

The Vision for Space Exploration has set the nation on a course to have humans on Mars as early as 2030. To reduce the cost and risk associated with human Mars exploration, NASA is planning for the Mars architecture to leverage the lunar architecture as fully as possible. This study takes the defined launch vehicles and system capabilities from ESAS and extends their application to DRM 3.0 to design an Earth Departure Stage suitable for the cargo and crew missions to Mars. The impact of a propellant depot in LEO was assessed and sLzed for use with the EDS. To quantitatively assess and compare the effectiveness of alternative designs, an initial baseline architecture was defined using the ESAS launch vehicles and DRM 3.0. The baseline architecture uses three NTR engines, LH2 propellant, no propellant depot in LEO, and launches on the Ares I and Ares V. The Mars transfer and surface elements from DRM 3.0 were considered to be fixed payloads in the design of the EDS. Feasible architecture alternatives were identified from previous architecture studies and anticipated capabilities and compiled in a morphological matrix. ESAS FOMs were used to determine the most critical design attributes for the effectiveness of the EDS. The ESAS-derived FOMs used in this study to assess alternative designs are effectiveness and performance, affordability, reliability, and risk. The individual FOMs were prioritized using the AHP, a method for pairwise comparison. All trades performed were evaluated with respect to the weighted FOMs, creating a Pareto frontier of equivalently ideal solutions. Additionally, each design on the frontier was evaluated based on its fulfillment of the weighted FOMs using TOPSIS, a quantitative method for ordinal ranking of the alternatives. The designs were assessed in an integrated environment using physics-based models for subsystem analysis where possible. However, for certain attributes such as engine type, historical, performance-based mass estimating relations were more easily employed. The elements from the design process were integrated into a single loop, allowing for rapid iteration of subsystem analyses and compilation of resulting designs.

Flaherty, Kevin↗

NASA NTRS2003

Electron Beam Freeform Fabrication: A Rapid Metal Deposition Process

Manufacturing of structural metal parts directly from computer aided design (CAD) data has been investigated by numerous researchers over the past decade. Researchers at NASA Langley REsearch Center are developing a new solid freeform fabrication process, electron beam freeform fabrication (EBF), as a rapid metal deposition process that works efficiently with a variety of weldable alloys. The EBF process introduces metal wire feedstock into a molten pool that is created and sustained using a focused electron beam in a vacuum environment. Thus far, this technique has been demonstrated on aluminum and titanium alloys of interest for aerospace structural applications nickel and ferrous based alloys are also planned. Deposits resulting from 2219 aluminum demonstrations have exhibited a range of grain morphologies depending upon the deposition parameters. These materials ave exhibited excellent tensile properties comparable to typical handbook data for wrought plate product after post-processing heat treatments. The EBF process is capable of bulk metal deposition at deposition rated in excess of 2500 cubic centimeters per hour (150 cubic inches per our) or finer detail at lower deposition rates, depending upon the desired application. This process offers the potential for rapidly adding structural details to simpler cast or forged structures rather than the conventional approach of machining large volumes of chips to produce a monolithic metallic structure. Selective addition of metal onto simpler blanks of material can have a significant effect on lead time reduction and lower material and machining costs.

Taminger, Karen M. B.↗

DOE OSTI2026

Toward a Climate OSSE Framework for Satellite Mission Design

The rich history of observing system simulation experiments (OSSEs) does not yet include a well-established framework for using climate models. The need for a climate OSSE is triggered by the need to quantify the value of a particular measurement for reducing the uncertainty in climate predictions, which differ from numerical weather predictions in that they depend on future atmospheric composition rather than the current state of the weather. However, both weather and climate modeling communities share a need for motivating major observing system investments. Here, we outline a new framework for climate OSSEs that leverages the use of machine learning to calibrate climate model physics against existing satellite data. We demonstrate its application using NASA’s GISS-E3 model to objectively quantify the value of potential future improvements in spaceborne measurements of Earth’s planetary boundary layer. A mature climate OSSE framework should be able to quantitatively compare the ability of proposed observing system architectures to answer a climate-related question, thus offering added value throughout the mission design process, which is subject to increasingly rapid advances in instrument and satellite technology. Technical considerations include selection of observational benchmarks and climate projection metrics, approaches to pinpoint the sources of model physics uncertainty that dominate uncertainty in projections, and the use of instrument simulators. Community and policy-making considerations include the potential to interface with an established culture of model intercomparison projects and a growing need to economically assess the value-driven efficiency of social spending on Earth observations.

54 ENVIRONMENTAL SCIENCES↗