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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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At least 37 records · Page 2
All sourcesNASA NTRSDOE OSTI
NASA NTRS2026

Prototype Demonstration of Solar Carbothermal System to Extract Oxygen from Regolith

The Carbothermal Reduction Demonstration (CaRD) project was an effort to develop a prototype system to demonstrate the extraction of oxygen from simulated lunar regolith using concentrated solar energy and a carbothermal reaction. The prototype consisted of a deployable solar concentrator capable of tracking the sun, carbothermal reactor, fluid system, gas analysis, and a solar concentrator control system consisting of avionics and software. These subsystems were developed by multiple NASA centers and a private industry partner, Sierra Space. The various teams worked together to define requirements and interfaces to successfully assemble the complex system and demonstrate an integrated solar carbothermal process. The solar concentrator developed at Glenn Research Center (GRC) was designed to be stowed for a launch environment then deployed on the lunar surface. It utilized a crossed dragone configuration of composite mirrors to direct horizontal sunlight onto a target 90° from the incoming sunlight. The key performance parameters for the solar concentrator were efficiency and power density. The carbothermal reactor was developed by Sierra Space through a separate project called the Carbothermal Oxygen Production Reactor (COPR) where it successfully demonstrated a fully automated process in a thermal vacuum environment. The fluid system needed for the carbothermal reaction was also developed by Sierra Space and successfully demonstrated in the same thermal vacuum test. The gas analysis system was developed at Kennedy Space Center (KSC) and was required to determine the amount of oxygen extracted during each test. The gas analysis system was based on the Mass Spectrometer Observing Lunar Operations (MSOLO) instrument. Avionics and software for the CaRD prototype were also developed at KSC and based on experience with MSOLO avionics and software. The control system was designed to stow, deploy, track the sun, and perform beam alignment of the concentrated light. The prototype subsystems were integrated and tested at Johnson Space Center’s (JSC) Energy Systems Test Area. A heliostat was used to direct sunlight toward the prototype in a way that is representative of the sunlight conditions at the south pole of the Moon. When concentrated sunlight was focused on simulated lunar regolith within the reactor, the gas analysis team confirmed the presence of carbon monoxide gas, which confirmed that a solar carbothermal reaction took place. The key performance parameter for the integrated prototype was grams of oxygen extracted per kilowatt hour of energy arriving at the concentrator primary mirror. The prototype design successfully demonstrated end-to-end capability and further steps to achieve a flight capable system have been defined. With lunar data, engineers would be able to design a scaled-up system capable of extracting oxygen from regolith at useful quantities for crew life support and rocket propellant. On the long term, this method of In-Situ Resource Utilization could be used to drastically reduce the cost and risk of a sustained human presence on the Moon by reducing the amount of oxygen that would have to be delivered.

Aaron Paz↗
NASA NTRS2026

Prototype Demonstration of an Integrated Solar Concentrator System and Carbothermal Reactor Using Solar Energy to Extract Oxygen from Regolith

The Carbothermal Reduction Demonstration (CaRD) project was an effort to develop a prototype system to demonstrate the extraction of oxygen from simulated lunar regolith using concentrated solar energy and a carbothermal reaction. The prototype consisted of a deployable solar concentrator capable of tracking the sun, carbothermal reactor, fluid system, gas analysis, and a solar concentrator control system consisting of avionics and software. These subsystems were developed by multiple NASA centers and a private industry partner, Sierra Space. The various teams worked together to define requirements and interfaces to successfully assemble the complex system and demonstrate an integrated solar carbothermal process. The solar concentrator developed at Glenn Research Center (GRC) was designed to be stowed for a launch environment then deployed on the lunar surface. It utilized a crossed dragone configuration of composite mirrors to direct horizontal sunlight onto a target 90° from the incoming sunlight. The key performance parameters for the solar concentrator were efficiency and power density. The carbothermal reactor was developed by Sierra Space through a separate project called the Carbothermal Oxygen Production Reactor (COPR) where it successfully demonstrated a fully automated process in a thermal vacuum environment. The fluid system needed for the carbothermal reaction was also developed by Sierra Space and successfully demonstrated in the same thermal vacuum test. The gas analysis system was developed at Kennedy Space Center (KSC) and was required to determine the amount of oxygen extracted during each test. The gas analysis system was based on the Mass Spectrometer Observing Lunar Operations (MSOLO) instrument. Avionics and software for the CaRD prototype were also developed at KSC and based on experience with MSOLO avionics and software. The control system was designed to stow, deploy, track the sun, and perform beam alignment of the concentrated light. The prototype subsystems were integrated and tested at Johnson Space Center’s (JSC) Energy Systems Test Area. A heliostat was used to direct sunlight toward the prototype in a way that is representative of the sunlight conditions at the south pole of the Moon. When concentrated sunlight was focused on simulated lunar regolith within the reactor, the gas analysis team confirmed the presence of carbon monoxide gas, which confirmed that a solar carbothermal reaction took place. The key performance parameter for the integrated prototype was grams of oxygen extracted per kilowatt hour of energy arriving at the concentrator primary mirror. The prototype design successfully demonstrated end-to-end capability and further steps to achieve a flight capable system have been defined. With lunar data, engineers would be able to design a scaled-up system capable of extracting oxygen from regolith at useful quantities for crew life support and rocket propellant. On the long term, this method of In-Situ Resource Utilization could be used to drastically reduce the cost and risk of a sustained human presence on the Moon by reducing the amount of oxygen that would have to be delivered.

Oxygen from Regolith↗
NASA NTRS2026

Prototype Demonstration of Solar-Carbothermal System to Extract Oxygen From Regolith

The Carbothermal Reduction Demonstration (CaRD) project was an effort to develop a prototype system to demonstrate the extraction of oxygen from simulated lunar regolith using concentrated solar energy and a carbothermal reaction. The prototype consisted of a deployable solar concentrator capable of tracking the sun, carbothermal reactor, fluid system, gas analysis, and a solar concentrator control system consisting of avionics and software. These subsystems were developed by multiple NASA centers and a private industry partner, Sierra Space. The various teams worked together to define requirements and interfaces to successfully assemble the complex system and demonstrate an integrated solar carbothermal process. The solar concentrator developed at Glenn Research Center (GRC) was designed to be stowed for a launch environment then deployed on the lunar surface. It utilized a crossed dragone configuration of composite mirrors to direct horizontal sunlight onto a target 90° from the incoming sunlight. The key performance parameters for the solar concentrator were efficiency and power density. The carbothermal reactor was developed by Sierra Space through a separate project called the Carbothermal Oxygen Production Reactor (COPR) where it successfully demonstrated a fully automated process in a thermal vacuum environment [1]. The fluid system needed for the carbothermal reaction was also developed by Sierra Space and successfully demonstrated in the same thermal vacuum test. The gas analysis system was developed at Kennedy Space Center (KSC) and was required to determine the amount of oxygen extracted during each test. The gas analysis system was based on the Mass Spectrometer Observing Lunar Operations (MSOLO) instrument. Avionics and software for the CaRD prototype were also developed at KSC and based on experience with MSOLO avionics and software. The control system was designed to stow, deploy, track the sun, and perform beam alignment of the concentrated light. The prototype subsystems were integrated and tested at Johnson Space Center’s (JSC) Energy Systems Test Area. A heliostat was used to direct sunlight toward the prototype in a way that is representative of the sunlight conditions at the south pole of the Moon. When concentrated sunlight was focused on simulated lunar regolith within the reactor, the gas analysis team confirmed the presence of carbon monoxide gas, which confirmed that a solar carbothermal reaction took place. The key performance parameter for the integrated prototype was grams of oxygen extracted per kilowatt hour of energy arriving at the concentrator primary mirror. The prototype design successfully demonstrated end-to-end capability and further steps to achieve a flight capable system have been defined. With lunar data, engineers would be able to design a scaled-up system capable of extracting oxygen from regolith at useful quantities for crew life support and rocket propellant. On the long term, this method of In-Situ Resource Utilization could be used to drastically reduce the cost and risk of a sustained human presence on the Moon by reducing the amount of oxygen that would have to be delivered.

Koorosh R Araghi↗
NASA NTRS2016

Building Blocks for Transport-Class Hybrid and Turboelectric Vehicles

NASA has been investing in research efforts to define potential vehicles that use hybrid and turboelectric propulsion to enable savings in fuel burn and carbon usage. This paper overviews the fundamental building blocks that have been derived from those studies and details what key performance parameters have been defined, what key ground and flight tests need to occur, and highlights progress toward each.

hybrid electric turboelectric aircraft elecric mac↗
NASA NTRS1996

High Performance Input/Output for Parallel Computer Systems

The goal of our project is to study the I/O characteristics of parallel applications used in Earth Science data processing systems such as Regional Data Centers (RDCs) or EOSDIS. Our approach is to study the runtime behavior of typical programs and the effect of key parameters of the I/O subsystem both under simulation and with direct experimentation on parallel systems. Our three year activity has focused on two items: developing a test bed that facilitates experimentation with parallel I/O, and studying representative programs from the Earth science data processing application domain. The Parallel Virtual File System (PVFS) has been developed for use on a number of platforms including the Tiger Parallel Architecture Workbench (TPAW) simulator, The Intel Paragon, a cluster of DEC Alpha workstations, and the Beowulf system (at CESDIS). PVFS provides considerable flexibility in configuring I/O in a UNIX- like environment. Access to key performance parameters facilitates experimentation. We have studied several key applications fiom levels 1,2 and 3 of the typical RDC processing scenario including instrument calibration and navigation, image classification, and numerical modeling codes. We have also considered large-scale scientific database codes used to organize image data.

Ligon, W. B.↗
NASA NTRS1990

A case study in nonconformance and performance trend analysis

As part of NASA's effort to develop an agency-wide approach to trend analysis, a pilot nonconformance and performance trending analysis study was conducted on the Space Shuttle auxiliary power unit (APU). The purpose of the study was to (1) demonstrate that nonconformance analysis can be used to identify repeating failures of a specific item (and the associated failure modes and causes) and (2) determine whether performance parameters could be analyzed and monitored to provide an indication of component or system degradation prior to failure. The nonconformance analysis of the APU did identify repeating component failures, which possibly could be reduced if key performance parameters were monitored and analyzed. The performance-trending analysis verified that the characteristics of hardware parameters can be effective in detecting degradation of hardware performance prior to failure.

Maloy, Joseph E.↗
DOE OSTI2022

Formulating energy density for designing practical lithium–sulfur batteries

We report the lithium–sulfur (Li–S) battery is one of the most promising battery systems due to its high theoretical energy density and low cost. Despite impressive progress in its development, there has been a lack of comprehensive analyses of key performance parameters affecting the energy density of Li–S batteries. Here, we analyse the potential causes of energy loss during battery operations. We identify two key descriptors (R weight and R energy ) that represent the mass- and energy-level compromise of the full-cell energy density, respectively. A formulation for energy density calculations is proposed based on critical parameters, including sulfur mass loading, sulfur mass ratio, electrolyte/sulfur ratio and negative-to-positive electrode material ratio. The current progress of Ah-level Li–S batteries is also summarized and analysed. Finally, future research directions, targets and prospects for designing practical high-performance Li–S batteries are proposed.

36 MATERIALS SCIENCE↗
NASA NTRS1989

Infrared thermal imaging figures of merit

Commercially available types of infrared thermal imaging instruments, both viewers (qualitative) and imagers (quantitative) are discussed. The various scanning methods by which thermal images (thermograms) are generated will be reviewed. The performance parameters (figures of merit) that define the quality of performance of infrared radiation thermometers will be introduced. A discussion of how these parameters are extended and adapted to define the performance of thermal imaging instruments will be provided. Finally, the significance of each of the key performance parameters of thermal imaging instruments will be reviewed and procedures currently used for testing to verify performance will be outlined.

Kaplan, Herbert↗
DOE OSTI2025

PID-Regulated Heating System for PIP-II Reference Line

The Proton Improvement Plan 2 (PIP-II) centers on building a new superconducting linear particle accelerator (Linac) at Fermilab. At the heart of the accelerator is the reference line. It is a critical system that defines the ideal path for the beam as it passes through magnets, RF cavities, and other beamline elements. Temperature stability is crucial for the reliable operation of RF components, such as mixers and filters. Fluctuations affect key performance parameters like conversion loss, isolation, and linearity. To mitigate any drift caused by ambient temperature changes, a heating plate assembly is utilized to maintain key components at a controlled temperature of 40 C. Utilizing an actively regulated heating system, a metal-oxide-semiconductor field-effect transistor (MOSFET) based power control circuit which provides input to a controller; forming a closed-loop system that maintains the desired setpoints with high precision.

Mosher, Alexander [U. Illinois, Chicago]↗
NASA NTRS2016

National Unmanned Aerial System Standardized Performance Testing and Rating (NUSTAR)

The overall objective of the NUSTAR Capability is to offer standardized tests and scenario conditions to assess performance of the UAS. The following are goals of the NU-STAR: 1. Create a prototype standardized tests and scenarios that vehicles can be tested against. 2. Identify key performance parameters of all UAS and their standardized measurement strategy. 3. Develop standardized performance reporting method (e.g., consumer report style) to assist prospective buyers. 4. Identify key performance metrics that could be used by judged towards overall safety of the UAS and operations. 5. If vehicle certification standard is made by a regulatory agency, the performance of individual UAS could be compared against the minimum requirement (e.g., sense and avoid detection time, stopping distance, kinetic energy, etc.).

Testing↗
DOE OSTI2025

PID-Regulated Heating System for PIP-II Reference Line

The Proton Improvement Project-2 centers on building a new superconducting linear particle accelerator (Linac) at Fermilab. At the heart of the accelerator is the reference line, a critical system that defines the ideal path for the particle beam as it passes through magnets, RF cavities, and other beamline elements. Temperature stability is crucial for the reliable operation of RF components, such as mixers and filters. Fluctuations affect key performance parameters like conversion loss, isolation, and linearity. To mitigate any drift caused by ambient temperature changes, a heating plate assembly is utilized to maintain key components at a controlled temperature of 40°C. The system utilizes an aluminum 36”x36”x0.5” heat plate powered by a MOSFET-based control circuit, delivering approximately 460 W of thermal energy through a resistor array. Real-time temperature feedback is provided by a PT100 Resistance Temperature Detector (RTD), which interfaces with a Proportional–Integral–Derivative (PID) control algorithm to maintain closed-loop temperature regulation. The control signal actively modulates the gate voltage of an N channel MOSFET, dynamically adjusting power delivery in response to deviations from the temperature setpoint. Simulations and LTspice models validate the functionality and responsiveness of the circuit under varying conditions. The prototype has successfully demonstrated stable thermal control, paving the way for integration into the PIP-II infrastructure. The final design will feature an expanded resistor array, as well as communication with a PLC for continuous data acquisition and diagnostics. This work directly supports Fermilab’s broader mission by contributing to the stability and reliability of core accelerator systems, enhancing the precision of particle beam delivery for future physics experiments.

Mosher, Alexander [Fermilab]↗
NASA NTRS2023

Transient Liquefaction on the Lunar or Martian Surface Operational Demonstration

The Cryogenic Fluid In-situ Liquefaction for Landers (CryoFILL) activity has been investigating concepts for the liquefaction of cryogenic fluids produced on the surface of the Moon and Mars. Liquefaction testing of oxygen in a scaled lander tank using an integrated, industrial cryocooler system was completed. The testing covered the determination of the nominal performance operation of the system, constant liquefaction performance, and transient liquefaction performance. The goal of the testing was to demonstrate cryogenic liquefaction operational capabilities on the Lunar and Martian surfaces for landers and In Situ Resource Utilization. The testing met all key performance parameter threshold values including liquefaction rate (demonstrated 1.6 kg/hr compared to threshold of 1.1 kg/hr), number of variables as transient (goal of 3: liquefaction flow, environmental temperature, and cryocooler input power – all demonstrated), and number of fill levels (goal of 3: < 5%, 50%, and 90% - all demonstrated). Key testing results from oxygen liquefaction testing will be discussed including sensitivities provided by the analysis team.

Liquefaction↗
NASA NTRSDate not supplied

A Technology Maturation Plan for the Development of Nuclear Electric Propulsion

Over the last two years NASA’s Space Nuclear Propulsion (SNP) Project formulated a Technology Maturation Plan (TMP) for development of the sub-systems needed for a MW-class Nuclear Electric Propulsion (NEP) system which, combined with a high thrust chemical propulsion stage, would be suitable for human missions to Mars. Two recent assessments, independently conducted by the National Academies for Science, Engineering, and Medicine and the NASA Engineering & Safety Center, concluded that the technologies required for a high-power NEP system are immature and the attendant risks insufficiently quantified to justify initiating a flight project. For NEP to be available as a viable option to meet flight opportunities in the late 2030s / 2040s time frame, development of the key sub-systems must begin now. SNP has subdivided the NEP system into five Critical Technology Elements (CTE): the nuclear reactor, power conversion, power management and distribution, electric propulsion sub-system, and the primary heat rejection system. Development plans for each of these CTEs have been drafted which will serve as the template for a focused milestone-driven research and development campaign intended to advance each CTE to Technology Readiness Level (TRL) 5. This will be accomplished by building and testing hardware at relevant power levels (~ 1 MW) and for relevant durations (2,500 hours, ~10% of the required operational lifetime) and conducting numerical modeling of the CTEs anchored by the accumulated test data to predict system performance and reliability. Concurrent with this work, high-level coupled system/mission modeling will be carried out to refine the key performance parameters that the various CTEs must achieve. Non-advocate reviews will be held at milestone points to assess progress and inform down-select decisions. The strategy for formulating the TMP was described previously; this paper describes ongoing progress on the drafting and baselining of the plan, including key specific details.

Space Nuclear Propulsion↗
NASA NTRSDate not supplied

A Technology Maturation Plan for the Development of Nuclear Electric Propulsion

Over the last two years NASA’s Space Nuclear Propulsion (SNP) Project formulated a Technology Maturation Plan (TMP) for development of the sub-systems needed for a MW-class Nuclear Electric Propulsion (NEP) system which, combined with a high thrust chemical propulsion stage, would be suitable for human missions to Mars. Two recent assessments, independently conducted by the National Academies for Science, Engineering, and Medicine and the NASA Engineering & Safety Center, concluded that the technologies required for a high-power NEP system are immature and the attendant risks insufficiently quantified to justify initiating a flight project. For NEP to be available as a viable option to meet flight opportunities in the late 2030s / 2040s time frame, development of the key sub-systems must begin now. SNP has subdivided the NEP system into five Critical Technology Elements (CTE): the nuclear reactor, power conversion, power management and distribution, electric propulsion sub-system, and the primary heat rejection system. Development plans for each of these CTEs have been drafted which will serve as the template for a focused milestone-driven research and development campaign intended to advance each CTE to Technology Readiness Level (TRL) 5. This will be accomplished by building and testing hardware at relevant power levels (~ 1 MW) and for relevant durations (2,500 hours, ~10% of the required operational lifetime) and conducting numerical modeling of the CTEs anchored by the accumulated test data to predict system performance and reliability. Concurrent with this work, high-level coupled system/mission modeling will be carried out to refine the key performance parameters that the various CTEs must achieve. Non-advocate reviews will be held at milestone points to assess progress and inform down-select decisions. The strategy for formulating the TMP was described previously*; this paper describes ongoing progress on the drafting and baselining of the plan, including key specific details. * “Strategy for Developing Technologies for Megawatt-class Nuclear Electric Propulsion Systems”, K.A. Polzin, et. al., International Electric Propulsion Conference IEPC 2022, IEPC-2022-155

Nuclear Electric Propulsion↗
NASA NTRS2016

Sizing Power Components of an Electrically Driven Tail Cone Thruster and a Range Extender

The aeronautics industry has been challenged on many fronts to increase efficiency, reduce emissions, and decrease dependency on carbon-based fuels. This paper provides an overview of the turboelectric and hybrid electric technologies being developed under NASA's Advanced Air Transportation Technology (AATT) Project and discusses how these technologies can impact vehicle design. The discussion includes an overview of key hybrid electric studies and technology investments, the approach to making informed investment decisions based on key performance parameters and mission studies, and the power system architectures for two candidate aircraft. Finally, the power components for a single-aisle turboelectric aircraft with an electrically driven tail cone thruster and for a hybrid-electric nine-passenger aircraft with a range extender are parametrically sized, and the sensitivity of these components to key parameters is presented.

hybrid propulsion↗
NASA NTRS2010

Optical Imaging and Radiometric Modeling and Simulation

OPTOOL software is a general-purpose optical systems analysis tool that was developed to offer a solution to problems associated with computational programs written for the James Webb Space Telescope optical system. It integrates existing routines into coherent processes, and provides a structure with reusable capabilities that allow additional processes to be quickly developed and integrated. It has an extensive graphical user interface, which makes the tool more intuitive and friendly. OPTOOL is implemented using MATLAB with a Fourier optics-based approach for point spread function (PSF) calculations. It features parametric and Monte Carlo simulation capabilities, and uses a direct integration calculation to permit high spatial sampling of the PSF. Exit pupil optical path difference (OPD) maps can be generated using combinations of Zernike polynomials or shaped power spectral densities. The graphical user interface allows rapid creation of arbitrary pupil geometries, and entry of all other modeling parameters to support basic imaging and radiometric analyses. OPTOOL provides the capability to generate wavefront-error (WFE) maps for arbitrary grid sizes. These maps are 2D arrays containing digital sampled versions of functions ranging from Zernike polynomials to combination of sinusoidal wave functions in 2D, to functions generated from a spatial frequency power spectral distribution (PSD). It also can generate optical transfer functions (OTFs), which are incorporated into the PSF calculation. The user can specify radiometrics for the target and sky background, and key performance parameters for the instrument s focal plane array (FPA). This radiometric and detector model setup is fairly extensive, and includes parameters such as zodiacal background, thermal emission noise, read noise, and dark current. The setup also includes target spectral energy distribution as a function of wavelength for polychromatic sources, detector pixel size, and the FPA s charge diffusion modulation transfer function (MTF).

Ha, Kong Q.↗
NASA NTRS2019

NASA Electrified Aircraft Propulsion Efforts

NASA's broad investments in Electrified Aircraft Propulsion (EAP) are reviewed in this paper. NASA investments are guided by an assessment of potential market impacts, technical key performance parameters, and technology readiness attained through a combination of studies, enabling fundamental research, and flight research. NASA has determined that the impact of EAP varies by market and NASA is considering three markets: national/international, on-demand mobility, and short haul regional air transport. Flight research is underway to demonstrate integrated solutions and inform standards and certification processes. This paper focuses on the vehicle related activities, however there are related NASA activities in air space management and vehicle autonomy activities as well as a breakthrough technology project called the Convergent Aeronautics Solutions Project. A key finding is that sufficient technical advances in key areas have been made which indicate EAP is a viable technology for aircraft. Significant progress has been made to reduce EAP adoption barriers and further work is needed to transition the technology to a commercial product and improve the technology so it is applicable to large transonic aircraft. This paper will review the activities of the Hybrid Gas Electric Subproject of the Advanced Air Transport Technology Project, the Revolutionary Vertical Lift Technology Project, and the X-57 Flight Demonstration Project, and discuss the potential EAP benefits for commercial and military applications.

Jansen, Ralph H.↗
DOE OSTI2021

Low-Cost Aero Technology Demonstrations

The main focus of this work was to demonstrate the use of polymeric additive manufacturing (AM) to create tooling for both preforming and consolidation. Polymeric tooling was utilized where both modest and higher pressures are used for part consolidation. The key focus for the AM tooling development was for fabrication of complex structures such as ducting, C-channel stiffened skins, and airfoils where conventional male tooling would typically be trapped in the cured part. The AM tooling was evaluated for use as a tool master used to fabricate and re-shape deformable/re-formable mandrels based on SpinTech’s shape memory composite technology known as Smart Tooling. The AM tooling was also evaluated for use as a mold for composite infusion and consolidation. Key performance parameters were tracked for project schedule completion with each step comprising of “art to part” cycle time, cost, and model fidelity for dimensions, performance, and cost. The primary focus of this demonstration was to determine if a 50% cost reduction was achievable, for each AM tooling-set, as compared to conventional processes. UDRI leveraged project partner SpinTech, who manufactures tools and parts in these categories and thus provided a baseline regarding current best practices and provided valuable feedback during the entirety of this demonstration. This demonstration primarily focused on the use of AM tooling for fabrication of three composite component structures which are typically utilized in aircraft and comprise salient geometric features of broad interest. These components are often tooling intensive and have features requiring extraction of male tools which are usually trapped by the geometry. The three structures selected by the team included: 1) A one-piece airfoil shell comprised of compound contours where male tooling would be trapped unless the part were manufactured in two halves as is typically the case. 2) A one-piece duct used for air handling, comprised of compound contours where male tooling would be trapped unless the part were manufactured in two halves, or a washout mandrel were to be used. 3) A co-cured C-channel stiffened skin where typically C-channels would be individually manufactured and then bonded to a cured skin. The demonstration was comprised of three main tasks: • Task 1: AM Tool Feasibility Study – ensure the AM tooling meets the performance requirements as specified by SpinTech to match baseline performance. • Task 2: Complex Tool Demonstration – Fabricate tooling, preforms, and parts representative of an airfoil and duct. • Task 3: Large Aerostructure Fabrication Demonstration – Fabricate tooling, preforms, and part representative of a C-channel stiffened skin. With the conclusion of this project, a decision tree was developed to determine the key considerations necessary to determine if use of AM tooling for the three selected structures was able to attain the same quality as historically achieved on metallic tooling, while providing a significant cost reduction.

36 MATERIALS SCIENCE↗