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NASA NTRS2001

The Challenges in the Development of a Long Duration Space Mission Food System

The Advanced Food System at Johnson Space Center/NASA will be responsible for supplying food to the crew for long duration exploratory missions. These missions require development of both a Transit Food System and of a Planetary Food System. The Transit Food System will consist of pre-packaged food of extended shelf life. It will be supplemented with salad crops that will be consumed fresh. The challenge is to develop a food system with a shelf life of 3 - 5 years that will use minimal power and create minimal waste from the food packaging. The Planetary Food System will allow for food processing of crops grown on the planetary surface due to the presence of some gravitational force. Crops will be processed to final products to provide a nutritious and acceptable diet for the crew. The food system must be flexible due to crop variation, availability, and shelf life. Crew meals, based on thesc: crops, must be nutritious, high quality, safe, and contain variety. The Advanced Food System becomes a fulcrum creating the right connection from crops to crew meals while dealing with issues of integration within a closed self-regenerative system (e.g., safety, waste production, volumes, water usage, etc.).

Perchonok, Michele H.↗

NASA NTRS1989

Growing plant in space

Space agencies in several countries are planning for the culture of plants in long duration space bases. The challenge of developing crop production procedures suitable for space projects will result in a new approach of problems we may meet today or in the near future in our common production systems. You may keep in mind subjects as: minimizing wastes or pollution problems, saving materials, introductions robotic helps. Discussion between scientists involved with food production for space programmes and protected horticultural cultivation may open new perspectives.

NASA Program CELSS↗

NASA NTRS2007

Propellant Analysis and Distillation Unit Design

The NASA White Sands Test Facility (WSTF) routinely operates hypergolic propulsion systems. Some of the onsite activities include performing long duration studies on the operational life of these systems. A few of them have been in use for over twenty years. During this span of time contamination has built up in the propellant and some of the distribution infrastructure. This study investigated the nature of this contamination, the pathology of its generation, and developed a process for removal of the contamination that was cost efficient with minimal waste generation.

Barragan, Michelle H.↗

NASA NTRS2007

Foods for a Mission to Mars: Equivalent System Mass and Development of a Multipurpose Small-Scale Seed Processor

The candidate crops for planetary food systems include: wheat, white and sweet potatoes, soybean, peanut, strawberry, dry bean including le ntil and pinto, radish, rice, lettuce, carrot, green onion, tomato, p eppers, spinach, and cabbage. Crops such as wheat, potatoes, soybean, peanut, dry bean, and rice can only be utilized after processing, while others are classified as ready-to-eat. To process foods in space, the food processing subsystem must be capable of producing a variety of nutritious, acceptable, and safe edible ingredients and food produ cts from pre-packaged and resupply foods as well as salad crops grown on the transit vehicle or other crops grown on planetary surfaces. D esigning, building, developing, and maintaining such a subsystem is b ound to many constraints and restrictions. The limited power supply, storage locations, variety of crops, crew time, need to minimize waste , and other equivalent system mass (ESM) parameters must be considere d in the selection of processing equipment and techniques.

Gandolph, J.↗

NASA NTRS2008

Electron Beam Freeform Fabrication: A Fabrication Process that Revolutionizes Aircraft Structural Designs and Spacecraft Supportability

The technological inception and challenges, as well as current applications of the electron beam freeform fabrication (EBF3) process are outlined. The process was motivated by the need for a new metals technology that would be cost-effective, enable the production of new alloys and that would could be used for efficient, lightweight structures. EBF3 is a rapid metal fabrication, layer-additive process that uses no molds or tools and which yields properties equivalent to wrought. The benefits of EBF3 include it near-net shape which minimizes scrap and reduces part count; efficiency in design which allows for lighter weight and enhanced performance; and, its "green" manufacturing process which yields minimal waste products. EBF3 also has a high tensile strength, while a structural test comparison found that EBF3 panels performed 5% lower than machined panels. Technical challenges in the EBF3 process include a need for process control monitoring and an improvement in localized heat response. Currently, the EBF3 process can be used to add details onto forgings and to construct and form complex shapes. However, it has potential uses in a variety of industries including aerospace, automotive, sporting goods and medical implant devices. The novel structural design capabilities of EBF3 have the ability to yield curved stiffeners which may be optimized for performance, low weight, low noise and damage tolerance applications. EBF3 has also demonstrated its usefulness in 0-gravity environments for supportability in space applications.

Taminger, Karen M.↗

NASA NTRS2016

Kennedy Space Center Five Year Sustainability Plan

The Federal Government is committed to following sustainable principles. At its heart, sustainability integrates environmental, societal and economic solutions for present needs without compromising the ability of future generations to meet their needs. Building upon its pledge towards environmental stewardship, the Administration generated a vision of sustainability spanning ten goals mandated within Executive Order (EO) 13693, Planning for Federal Sustainability in the Next Decade. In November 2015, the National Aeronautics and Space Administration (NASA) responded to this EO by incorporating it into a new release of the NASA Strategic Sustainability Performance Plan (SSPP). The SSPP recognizes the importance of aligning environmental practices in a manner that preserves, enhances and strengthens NASA's ability to perform its mission indefinitely. The Kennedy Space Center (KSC) is following suit with KSC's Sustainability Plan (SP) by promoting, maintaining and pioneering green practices in all aspects of our mission. KSC's SP recognizes that the best sustainable solutions use an interdisciplinary, collaborative approach spanning civil servant and contractor personnel from across the Center. This approach relies on the participation of all employees to develop and implement sustainability endeavors connected with the following ten goals: Reduce greenhouse gas (GHG) emissions. Design, build and maintain sustainable buildings, facilities and infrastructure. Leverage clean and renewable energy. Increase water conservation. Improve fleet and vehicle efficiency and management. Purchase sustainable products and services. Minimize waste and prevent pollution. Implement performance contracts for Federal buildings. Manage electronic equipment and data centers responsibly. Pursue climate change resilience. The KSC SP details the strategies and actions that address the following objectives: Reduce Center costs. center dot Increase energy and water efficiencies. Promote smart buying practices. Increase reuse and recycling while decreasing waste. Benefit the community. Meet or exceed the EO and NASA SSPP sustainability goals.

Sustainability↗

NASA NTRS2017

The Pulsed Fission-Fusion (PUFF) Concept for Deep Space Exploration and Terrestrial Power Generation

This team is exploring a modified Z-pinch geometry as a propulsion system, imploding a liner of liquid lithium onto a pellet containing both fission and fusion fuel. The plasma resulting from the fission and fusion burn expands against a magnetic nozzle, for propulsion, or a magnetic confinement system, for terrestrial power generation. There is considerable synergy in the concept; the lithium acts as a temporary virtual cathode, and adds reaction mass for propulsion. Further, the lithium acts as a radiation shield against generated neutrons and gamma rays. Finally, the density profile of the column can be tailored using the lithium sheath. Recent theoretical and experimental developments (e.g. tailored density profile in the fuel injection, shear stabilization, and magnetic shear stabilization) have had great success in mitigating instabilities that have plagued previous fusion efforts. This paper will review the work in evaluating the pellet sizes and z-pinch conditions for optimal PuFF propulsion. Trades of pellet size and composition with z-pinch power levels and conditions for the tamper and lithium implosion are evaluated. Current models, both theoretical and computational, show that a z-pinch can ignite a small (~1 cm radius) fission-fusion target with significant yield. Comparison is made between pure fission and boosted fission targets. Performance is shown for crewed spacecraft for high speed Mars round trip missions and near interstellar robotic missions. The PuFF concept also offers a solution for terrestrial power production. PuFF can, with recycling of the effluent, achieve near 100% burnup of fission fuel, providing a very attractive power source with minimal waste. The small size of PuFF relative to today's plants enables a more distributed power network and less exposure to natural or man-made disruptions.

Adams, Robert↗

NASA NTRS2018

Geometry and Joint Systems for Lattice-Based Reconfigurable Space Structures

We describe analytical methods for the design of the discrete elements of ultralight lattice structures. This modular, building block strategy allows for relatively simple element manufacturing, as well as relatively simple robotic assembly of low mass density structures on orbit, with potential for disassembly and reassembly into highly varying and large structures. This method also results in a structure that is easily navigable by relatively small mobile robots. The geometry of the cell can allow for high packing efficiency to minimize wasted payload volume while maximizing structural performance and constructability. We describe the effect of geometry choices on the final system mechanical properties, manufacturability of the components, and automated robotic constructability of a final system. Geometry choices considered include building block complexity, symmetry of the unit cell, and effects of vertex, edge, and face connectivity of the unit cell. Mechanical properties considered include strength scaling, modulus scaling, and structural performance of the joint, including proof load, shear load, mass, and loading area; as well as validation and verification opportunities. Manufacturability metrics include cost and time, manufacturing method (COTS versus custom), and tolerances required. Automated constructability metrics include local effects of loads imparted to the structure by the robot and assembly complexity, encompassing the ability of the robot to clamp and number of placement motions needed for assembly.

Ochalek, Megan E.↗

NASA NTRS2019

Geometry Systems for Lattice-Based Reconfigurable Space Structures

We describe analytical methods for the design of the discrete elements of ultralight lattice structures. This modular, building block strategy allows for relatively simple element manufacturing, as well as relatively simple robotic assembly of low mass density structures on orbit, with potential for disassembly and reassembly into highly varying and large structures. This method also results in a structure that is easily navigable by relatively small mobile robots. The geometry of the cell can allow for high packing efficiency to minimize wasted payload volume while maximizing structural performance and constructability. We describe the effect of geometry choices on the final system mechanical properties and automated robotic constructability of a final system. Geometric properties considered include number of attachments per voxel, number of attachments per coefficient of volume, and effects of vertex, edge, and face connectivity of the unit cell. Mechanical properties considered include strength scaling, modulus scaling, and packing efficiency of the lattice. Automated constructibility metrics include volume allowance for an end-effector, strut clearance angle for an end-effector, and packing efficiency. These metrics were applied to six lattice unit cell geometries: cube, cuboctahedron, octahedron, octet, rhombic dodecahedron, and truncated octahedron. A case study is presented to determine the most suitable lattice system for a specific set of strength and modulus scaling requirements while optimizing for ease of robotic assembly.

lattice geometry↗

NASA NTRSDate not supplied

Geometry Systems for Lattice-Based Reconfigurable Space Structures

We describe analytic methods for the design of the discrete elements of ultralight lattice structures. This modular building block strategy allows for relatively simple element manufacturing as well as relatively simple robotic assembly of low mass-density structures on orbit, with potential for disassembly and reassembly into highly varying and large structures. This method also results in a structure that is easily navigable by relatively small, mobile robots. The geometry of the cell can allow for high packing efficiency to minimize wasted payload volume while maximizing structural performance and constructability. We describe the effect of geometry choices on the mechanical properties and automated robotic constructability of a final system. Geometric properties considered include number of attachments per voxel, number of attachments per coefficient of volume, and effects of vertex, edge, and face connectivity of the unit cell. Mechanical properties considered include strength scaling, modulus scaling, and packing efficiency of the lattice. Automated constructibility metrics include volume allowance for an end-effector, strut clearance angle for an end-effector, and packing efficiency. These metrics were applied to six lattice unit cell geometries: cube, cuboctahedron, octahedron, octet, rhombic dodecahedron, and truncated octahedron. A case study is presented to determine the most suitable lattice system for a specific set of strength and modulus scaling requirements while optimizing for ease of robotic assembly.

digital materials↗

NASA NTRSDate not supplied

Surviving and Thriving in Space and on Earth's Oceans - Human Logistics and Sustainability Comparisons and Considerations

The human species has a yearning for exploration as evidenced by the extensive historical ocean voyages and expeditions which have led to a massive advancement in the scientific and geodetic knowledge about planet Earth. These global explorations via the oceans have also had strategic, economic, cultural and religious implications and impacts, which have drastically changed the state of humanity and its condition. The transportation network created by ships traveling across the oceans has been supplemented by other transportation networks on land and in the air, creating a global economy that, in general, has improved the human condition leading to better health, longer lives, lower child mortality, better education, political freedom, higher gross national product (GNP) and improved hygiene. The logical extension of this societal trend is to extend the transportation network and human civilization into outer space, beyond the cradle of planet Earth. Our solar system contains vast amounts of natural resources which can be harnessed and used to bootstrap a space economy and related infrastructure by using advanced technologies. Sailing journeys from hundreds of years ago required large vessels and large crews, (in comparison with today’s space capsules). Modern sailors of today are able to complete large voyages, in small vessels, with a minimal crew, comparable in magnitude to modern space travel. This paper will use a systems engineering approach (e.g. using the NASA Human Integration Design Handbook (HIDH), NASA-SP-2010-3407, 2010 and the “Advanced Life Support Baseline Values and Assumptions Document, (BVAD)” NASA-CR-2004-208941, 2004.), to examine and compare the logistics and sustainability aspects of a small crew traveling on Earth's oceans in sailing vessels versus humans traveling in space. The “Mālama Honua Worldwide Voyage” of the Hokule’a, a replica of an ancient Hawaiian double hulled sailing canoe, will be used as a case study. This is the best comparison case since the Polynesian exploration of the vast (and virtually empty) Pacific Ocean is the closest analogue to modern space travel. “"Both are voyages of exploration.” –Shuttle astronaut Lacy Veach. Minimizing waste and maximizing re-use and re-cycling will lead to more efficient logistics and sustainability. In addition, In-Situ Resource Utilization (ISRU) strategies, based on successful Earth based strategies used for many years by sailors will be considered and evaluated for their usefulness. For example, human logistics for a typical space mission are shown in Table 1 and Table 2 (Lopez et al, 2015). Studies show that typical human water consumption in space is projected to be 3.2 kg/day per crew member as shown in Table 2. Data from human sailing voyages around the globe will be examined. Anecdotal evidence indicates that knowledgeable and well-equipped modern sailors, who conserve water, can comfortably live using 1.5 to 5 kg/day per person. This paper will investigate key logistics and sustainability aspects of living in space and compare them quantitatively to similar aspects of living on ocean faring sailing vessels on Earth. Mutually beneficial observations, advanced technologies and modern considerations will be applied within confines of a remote sailing environment, which could be of immense value to both the space faring community and the ocean sailing community.

Space↗

NASA NTRS2003

Fuel cell environmental life cycle assessment : a progress report

Energy generation using fuel cells offers the possibility of high conversion efficiency and reduced pollution. Thus, in the futue, conventional methods of energy generation using coalfired power plants, natural gas turbines and internal combustion engines can potentially be replaced by fuel cells. The United States, Japan and several countries in Europe are currently developing fuel cells for transportation, distributed energy generation and portable electronics applications. On a system basis, the efficiency of chemical to electrical energy conversion in fuel cells can be as high as 45%. Also, because of the lower operating temperatures compared to turbines and internal combustion engines, emissions such as carbon monoxide and nitrogen oxides are extremely small. An assessment of the environmental impact of fuel cells over the entire lifecycle is needed to determine the specific benefits in various application scenarios. Such a comparative pollutants assessment must include a "cradle to grave" approach encompassing fuel production, fuel transportation, materials/manufacturing processes, waste management, and recycling. A comparative pollutant model would be a useful tool for industry and government in estimating energy savings and environmental credits, and providing a holistic understanding on regulatory needs. Another important benefit would be the ability to make appropriate comparisons with competitive energy generation technologies such as hybrids, turbines, and internal combustion engines, and to set up realistic targets. Also, exercising the model will assist in the initial screening for potential hot spots and showstoppers and focus on the right component technologies design for manufacturing, designs for input substitution and waste minimization, and prevent any unforeseen burdens.

Narayanan, S. R.↗

NASA NTRSDate not supplied

Demonstration of How Manufacturing Innovations Challenge Conventional Structural Design

For almost 100 years, commercial aircraft have been fabricated using riveted aluminum alloy structures. Aside from refining aircraft designs for better aerodynamic efficiency, improving alloy compositions, and automating assembly steps, fuselage construction remains largely unchanged today. The intent of the lightweight metallic fuselage prototype undertaken in NASA’s Advanced Air Transport Technology project was to demonstrate innovative forming and joining processes that advance the design paradigm, i.e. achieve high-rate manufacturing and reduce assembly time/costs. Over the past decade, researchers at NASA Langley Research Center have evaluated the potential to modify the flow forming process to produce near-net shaped cylinders, integrally stiffened along the cylinder axis, for space launch vehicles. The production of integral stiffeners in a formed aluminum cylinder, the size of the Space Shuttle external tank, replaced machined thick plate and welding steps to eliminate > 500,000 pounds of machining chips and ~ 0.5 miles of welds. The flow forming method, called the Integrally Stiffened Cylinder (ISC) process, was successfully demonstrated up to the 10-foot diameter scale, which laid the groundwork for the current investigation of metallic fuselage structures. Using the ISC process as the basis for the re-design of a metallic fuselage eliminates hundreds of thousands of holes and rivets, while significantly reducing assembly time and crack initiation sites in the integral structure. However, the ISC process is not currently configured to fabricate circumferential ring frames for carrying fuselage internal pressure loads. Consequently, a trade study was performed to assess existing and advanced manufacturing processes, including additive manufacturing, forming, and welding. The approach with the lowest barriers to success, while simultaneously improving manufacturing time and cost, was to use formed ring frame segments attached to the ISC via Refill Friction Stir Spot Welding (RFSSW). The RFSSW process is five times faster than drilling, reaming, and riveting and provides similar mechanical performance. Finishing the fuselage structure with conventional windows, floor beams, and floor panels can then be accomplished using incumbent assembly methods, thereby maximizing reuse of existing infrastructure for aircraft construction. Structural analyses were performed to assess and optimize the geometric variables of integrated skin and stiffener configurations. A cost benefit and manufacturing rate analysis was also performed to compare against the current state-of-the-art for single aisle transport class aircraft. The resulting structure offers a weight reduction that rivals current graphite-epoxy composite fuselage structures. The projected manufacturing rate is close to double current metallic fuselages and six times faster than current composite manufacturing practices. The damage tolerance properties of a monocoque fuselage structure have yet to be assessed, but past integral airframe structural work has exploited geometric features to blunt or turn cracks. This concept offers promise that integrated structures can meet stringent aircraft durability specifications. An important benefit is that such aluminum fuselage structures may be inspected and repaired using established practices and existing expertise. Finally, pursuit of advanced manufacturing processes for future aluminum fuselages minimizes waste and the structure is 100% recyclable at the end-of-life for maximum sustainability.

aluminum↗

NASA NTRSDate not supplied

Mass Economy Evaluation for Integrated ECLSS and Propulsion Architecture

As missions in Low Earth Orbit (LEO) lengthen and extend to deep space, minimizing resupply needs becomes vital for sustaining crewed operations. Traditional life support systems depend on consumables resupplied from Earth, a method that is increasingly impractical for missions beyond LEO, such as lunar outposts or Mars transit. Long-duration missions require more efficient, autonomous systems that can recycle essential resources, particularly water and oxygen, to minimize the frequency and mass of resupply missions. The Environmental Control and Life Support System (ECLSS) is essential to such missions, with the International Space Station (ISS) serving as a testbed for advanced water recovery and partial oxygen recycling via physico-chemical methods. Yet, ECLSS and propulsion subsystems generally operate independently, despite overlapping requirements and potential areas for synergy. For instance, ECLSS byproducts, water, CO₂, and hydrogen, could be repurposed for propulsion, potentially reducing dedicated propellant mass and increasing overall system efficiency. One promising approach is to develop shared-resource architectures that integrate ECLSS with propulsion systems. This study examines the potential of such integration through the Sabatier CO₂ reduction process, focusing on water management as a key factor in system mass trade-offs. The Sabatier reaction produces water and methane from metabolic CO₂ and electrolytic hydrogen, partially closing the life support loop and providing methane, which could serve as a propellant. This integration could minimize waste, reduce resupply requirements, and enhance mission mass efficiency. A dynamic modeling framework will be used to simulate resource flows over long missions, capturing interactions between life support and propulsion. By comparing integrated versus separate system configurations, the study aims to quantify mass benefits and penalties, informing future habitat designs and trade studies for missions prioritizing autonomy and mass efficiency.

ECLSS↗

NASA NTRS2026

Mass Economy Evaluation for Integrated ECLSS and Propulsion Architecture

As missions in low Earth orbit (LEO) lengthen and extend to deep space, minimizing resupply needs becomes vital for sustaining crewed operations. Traditional life support systems depend on consumables resupplied from Earth, a method that is increasingly impractical for missions beyond LEO, such as lunar outposts or Mars transit. Long-duration missions require more efficient, autonomous systems that can recycle essential resources, particularly water and oxygen, to minimize the frequency and mass of resupply missions. The Environmental Control and Life Support System (ECLSS) is essential to such missions, with the International Space Station (ISS) serving as a testbed for advanced water recovery and partial oxygen recycling via physico-chemical methods. Yet, ECLSS and propulsion subsystems generally operate independently, despite overlapping requirements and potential areas for synergy. For instance, ECLSS byproducts, water, CO 2 , and hydrogen, could be repurposed for propulsion, potentially reducing dedicated propellant mass and increasing overall system efficiency. One promising approach is to develop shared-resource architectures that integrate ECLSS with propulsion systems. This study examines the potential of such integration through the Sabatier CO₂ reduction process, focusing on water management as a key factor in system mass trade-offs. The Sabatier reaction produces water and methane from metabolic CO 2 and electrolytic hydrogen, partially closing the life support loop and providing methane, which could serve as a propellant. This integration could minimize waste, reduce resupply requirements, and enhance mission mass efficiency. A dynamic modeling framework will be used to simulate resource flows over long missions, capturing interactions between life support and propulsion. By comparing integrated versus separate system configurations, the study aims to quantify mass benefits and penalties, informing future habitat designs and trade studies for missions prioritizing autonomy and mass efficiency.

ECLSS↗

NASA NTRS2013

Trash-to-Gas: Using Waste Products to Minimize Logistical Mass During Long Duration Space Missions

Just as waste-to-energy processes utilizing municipal landftll and biomass wastes are finding increased terrestrial uses, the Trash-to-Gas (TtG) project seeks to convert waste generated during spaceflight into high value commodities. These include methane for propulsion and water for life support in addition to a variety of other gasses. TtG is part of the Logistic Reduction and Repurposing (LRR) project under the NASA Advanced Exploration Systems Program. The LRR project will enable a largely mission-independent approach to minimize logistics contributions to total mission architecture mass. LRR includes technologies that reduce the amount of consumables that need to be sent to space, repurpose items sent to space, or convert wastes to commodities. Currently, waste generated on the International Space Station is stored inside a logistic module which is de-orbited into Earth's atmosphere for destruction. The waste consists of food packaging, food, clothing and other items. This paper will discuss current results on incineration as a waste processing method. Incineration is part of a two step process to produce methane from waste: first the waste is converted to carbon oxides; second, the carbon oxides are fed to a Sabatier reactor where they are converted to methane. The quantities of carbon dioxide, carbon monoxide, methane and water were measured under the different thermal degradation conditions. The overall carbon conversion efficiency and water recovery are discussed.

Hintze, Paul. E.↗

NASA NTRS2013

Trash-to-Gas: Using Waste Products to Minimize Logistical Mass During Long Duration Space Missions

Hintze, Paul E.↗

NASA NTRSDate not supplied

Waste Container Filtration To Minimize Microbial Escape During Long-Term Storage On Mars

In the search for life on Mars, keeping its surface pristine and free of microbes due to human presence is of utmost importance. Astronauts will use emptied logistics containers during their Martian stay to store waste. These containers will be left on the planet’s surface and are a potential source of microbial contamination. It is desired for these containers to be free from leaks for a minimum of 50 years. If leaks do occur a likely location will be at the port. At this location the mating surfaces will be sealed using a flexible gasket material like a thin metal or a polymer. Eventually these seals will fail. To mitigate these effects, a particulate filter can be employed to equilibrate the pressure between the Martin environment and inside the container. To meet planetary protection requirements, the filter can only allow particulates smaller than 0.2 um diameter to pass. This paper discusses why a particulate filter may be needed and how such a filter would be tested to survive and operate in the harsh Martian environment.

Planetary Protection Waste Containment↗