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At least 487 records · Page 27

Human Factors in Virtual Reality Development

This half-day tutorial will provide an overview of basic perceptual functioning as it relates to the design of virtual environment systems. The tutorial consists of three parts. First, basic issues in visual perception will be presented, including discussions of the visual sensations of brightness and color, and the visual perception of depth relationships in three-dimensional space (with a special emphasis on motion -specified depth). The second section will discuss the importance of conducting human-factors user studies and evaluations. Examples and suggestions on how best to get help with user studies will be provided. Finally, we will discuss how, by drawing on their complementary competencies, perceptual psychologists and computer engineers can work as a team to develop optimal VR systems, technologies, and techniques.

Kaiser, Mary K.↗

Software forecasting as it is really done: A study of JPL software engineers

This paper presents a summary of the results to date of a Jet Propulsion Laboratory internally funded research task to study the costing process and parameters used by internally recognized software cost estimating experts. Protocol Analysis and Markov process modeling were used to capture software engineer's forecasting mental models. While there is significant variation between the mental models that were studied, it was nevertheless possible to identify a core set of cost forecasting activities, and it was also found that the mental models cluster around three forecasting techniques. Further partitioning of the mental models revealed clustering of activities, that is very suggestive of a forecasting lifecycle. The different forecasting methods identified were based on the use of multiple-decomposition steps or multiple forecasting steps. The multiple forecasting steps involved either forecasting software size or an additional effort forecast. Virtually no subject used risk reduction steps in combination. The results of the analysis include: the identification of a core set of well defined costing activities, a proposed software forecasting life cycle, and the identification of several basic software forecasting mental models. The paper concludes with a discussion of the implications of the results for current individual and institutional practices.

Griesel, Martha Ann↗

Applications of Federated Learning in Semiconductor Manufacturing [Poster]

As semiconductor manufacturers explore advanced data analytics and modeling techniques and data hungry machine learning models increase in popularity due to their accuracy in solving generalized problems and ability to learn complex relationships, federated learning emerges as a privacy preserving machine learning technique for preserving data privacy and ensuring intellectual property protection. Federated Learning is a machine learning technique focused on training models using distributed data that never needs to be centrally stored, allowing the use of advanced machine learning techniques without compromising data privacy, and in the semiconductor manufacturing industry advanced machine learning techniques can reduce cost and time, but maintaining data privacy is essential to maintaining a competitive advantage. This paper systematically reviews existing literature on applications of federated learning in the semiconductor manufacturing industry with a focus on identifying common themes, algorithms, and gaps within the literature to drive future research directions. The findings reveal five key themes, including improvements in quality assurance, virtual models, privacy preservation, reliable data practices, and emerging trends and developments. By identifying key themes in literature on federated learning and semiconductor manufacturing and analyzing gaps and discussed methodologies, this study highlights several potential future research directions to expand the application of federated learning techniques in the semiconductor manufacturing domain.

42 ENGINEERING↗

Formation Control for the MAXIM Mission

Over the next twenty years, a wave of change is occurring in the space-based scientific remote sensing community. While the fundamental limits in the spatial and angular resolution achievable in spacecraft have been reached, based on today s technology, an expansive new technology base has appeared over the past decade in the area of Distributed Space Systems (DSS). A key subset of the DSS technology area is that which covers precision formation flying of space vehicles. Through precision formation flying, the baselines, previously defined by the largest monolithic structure which could fit in the largest launch vehicle fairing, are now virtually unlimited. Several missions including the Micro-Arcsecond X-ray Imaging Mission (MAXIM), and the Stellar Imager will drive the formation flying challenges to achieve unprecedented baselines for high resolution, extended-scene, interferometry in the ultraviolet and X-ray regimes. This paper focuses on establishing the feasibility for the formation control of the MAXIM mission. MAXIM formation flying requirements are on the order of microns, while Stellar Imager mission requirements are on the order of nanometers. This paper specifically addresses: (1) high-level science requirements for these missions and how they evolve into engineering requirements; and (2) the development of linearized equations of relative motion for a formation operating in an n-body gravitational field. Linearized equations of motion provide the ground work for linear formation control designs.

Luquette, Richard J.↗

Quantification of Plume-Soil Interaction and Excavation Due to the Sky Crane Descent Stage

The quantification of the particulate erosion that occurs as a result of a rocket exhaust plume impinging on soil during extraterrestrial landings is critical for future robotic and human lander mission design. The aerodynamic environment that results from the reflected plumes results in dust lifting, site alteration and saltation, all of which create a potentially erosive and contaminant heavy environment for the lander vehicle and any surrounding structures. The Mars Science Lab (MSL), weighing nearly one metric ton, required higher levels of thrust from its retro propulsive systems and an entirely new descent system to minimize these effects. In this work we seek to quantify plume soil interaction and its resultant soil erosion caused by the MSL's Sky Crane descent stage engines by performing three dimensional digital terrain and elevation mapping of the Curiosity rover's landing site. Analysis of plume soil interaction altitude and time was performed by detailed examination of the Mars Descent Imager (MARDI) still frames and reconstructed inertial measurement unit (IMU) sensor data. Results show initial plume soil interaction from the Sky Crane's eight engines began at ground elevations greater than 60 meters and more than 25 seconds before the rovers' touchdown event. During this time, viscous shear erosion (VSE) was dominant typically resulting in dusting of the surface with flow propagating nearly parallel to the surface. As the vehicle descended and decreased to four powered engines plume-plume and plume soil interaction increased the overall erosion rate at the surface. Visibility was greatly reduced at a height of roughly 20 meters above the surface and fell to zero ground visibility shortly after. The deployment phase of the Sky Crane descent stage hovering at nearly six meters above the surface showed the greatest amount of erosion with several large particles of soil being kicked up, recirculated, and impacting the bottom of the rover chassis. Image data obtained from MSL's navigation camera (NAVCAM) pairs on Sols 002, 003, and 016 were used to virtually recreate local surface topography and features around the rover by means of stereoscopic depth mapping. Images taken simultaneously by the left and right navigation cameras located on the rover's mast assembly spaced 42 centimeters were used to generate a three dimensional depth map from flat, two dimensional images of the same feature at slightly different angles. Image calibration with physical hardware on the rover and known terrain features were used to provide scaling information that accurately sizes features and regions of interest within the images. Digital terrain mapping analysis performed in this work describe the crater geometry (shape, radius, and depth), eroded volume, volumetric erosion rate, and estimated mass erosion rate of the Hepburn, Sleepy Dragon, Burnside, and Goulburn craters. Crater depths ranged from five to ten centimeters deep influencing an area as wide as two meters in some cases. The craters formed were highly asymmetrical and generally oblong primarily due to the underlying bedrock formations underneath the surface. Comparison with ground tests performed at the NASA AMES Planetary Aeolian Laboratory (PAL) by Mehta showed good agreement with volumetric erosion rates and crater sizes of large particle soil simulants, providing validation to Earth based ground tests of Martian regolith.

Vizcaino, Jeffrey↗

New Observing Strategies Testbed (NOS-T)

The New Observing Strategies (NOS) initiative within the NASA Earth Science Technology Office(ESTO)Advanced Information Systems Technology(AIST) program envisions future Earth science missions with distributed sensors(nodes) interconnected by a communications fabric that enables dynamic and intelligent operations [1].Some NOS concepts resemble systems-of-systems or collaborative systems where operational authority is distributed among multiple systems, necessitating new methods for systems engineering and design to cope with more decentralized control over constituent systems[2].The New Observing Strategies Testbed (NOS-T, verbalized as "enoh es tee") is a computational environment to develop, test, mature, and socialize new operating concepts and technology for NOS. NOS-T provides infrastructure to integrate and orchestrate user-contributed applications for system-of-systems test cases with true distributed control over constituent systems. The overall concept, illustrated in Figure 1, interconnects individual user applications and a NOS-T manager application via common information system infrastructure to coordinate the execution of virtual Earth science missions. NOS-T enables principal investigators to conduct test runs in the same environment, systematically changing variables to assess the overall efficacy of the proposed new observing strategies. Recorded data and outcomes provide evidence to advance technology readiness level and improve or innovate upon existing Earth science measurement techniques

Paul Grogan↗

Controlling Infrastructure Costs: Right-Sizing the Mission Control Facility

Johnson Space Center's Mission Control Center is a space vehicle, space program agnostic facility. The current operational design is essentially identical to the original facility architecture that was developed and deployed in the mid-90's. In an effort to streamline the support costs of the mission critical facility, the Mission Operations Division (MOD) of Johnson Space Center (JSC) has sponsored an exploratory project to evaluate and inject current state-of-the-practice Information Technology (IT) tools, processes and technology into legacy operations. The general push in the IT industry has been trending towards a data-centric computer infrastructure for the past several years. Organizations facing challenges with facility operations costs are turning to creative solutions combining hardware consolidation, virtualization and remote access to meet and exceed performance, security, and availability requirements. The Operations Technology Facility (OTF) organization at the Johnson Space Center has been chartered to build and evaluate a parallel Mission Control infrastructure, replacing the existing, thick-client distributed computing model and network architecture with a data center model utilizing virtualization to provide the MCC Infrastructure as a Service. The OTF will design a replacement architecture for the Mission Control Facility, leveraging hardware consolidation through the use of blade servers, increasing utilization rates for compute platforms through virtualization while expanding connectivity options through the deployment of secure remote access. The architecture demonstrates the maturity of the technologies generally available in industry today and the ability to successfully abstract the tightly coupled relationship between thick-client software and legacy hardware into a hardware agnostic "Infrastructure as a Service" capability that can scale to meet future requirements of new space programs and spacecraft. This paper discusses the benefits and difficulties that a migration to cloud-based computing philosophies has uncovered when compared to the legacy Mission Control Center architecture. The team consists of system and software engineers with extensive experience with the MCC infrastructure and software currently used to support the International Space Station (ISS) and Space Shuttle program (SSP).

Martin, Keith↗

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↗

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

Ocean exploration sailing journeys from hundreds of years ago typically required large vessels and large crews (in comparison with today’s space capsules) to travel between the continents and around the world. Modern sailors of today are able to complete similar distant voyages, in small vessels, with a minimal crew, comparable in size to modern space travel crews. This paper uses 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 Hōkūleʻa, a replica of an ancient Hawaiian double hulled sailing canoe, will be used as a baseline minimalist case study. This is a good comparison case since the Polynesian exploration of the vast (and virtually empty) Pacific Ocean with limited resources is an analogue to human space travel. A modern sailboat is compared to the ancient Polynesian methods and then a space craft is assessed with similar functional decomposition methods. In 1992 during his second Space Shuttle mission (STS-52, Columbia) Astronaut Lacy Veach received a radio message from a student: "What are the similarities and differences between canoe and space travel?" Astronaut Charles Lacy Veach answered, "Both are voyages of exploration. Hōkūle‘a is in the past, Columbia is in the future." Navigator Nainoa Thompson added from the sailing canoe, "Columbia is the highest achievement of modern technology today, a voyaging canoe was the highest achievement of technology in its day." This paper is dedicated to the memory of two great Hawaiian astronauts: US Air Force Colonel Charles Lacy Veach and US Air Force Colonel Ellison Onizuka and to legendary waterman and Hōkūleʻa crew member Eddie Aikau who was lost at sea in 1978, at the beginning of a 30-day, 2,500-mile (4,000km) journey by the Hōkūleʻa to follow the ancient route of the Polynesian migration between the Hawaiian and Tahitian island chains.

Robert P Mueller↗

Reconfigurable HIL Testing of Earth Satellites

In recent years, hardware-in-the-loop (HIL) testing has carved a strong niche in several industries, such as automotive, aerospace, telecomm, and consumer electronics. As desktop computers have realized gains in speed, memory size, and data storage capacity, hardware/software platforms have evolved into high performance, deterministic HIL platforms, capable of hosting the most demanding applications for testing components and subsystems. Using simulation software to emulate the digital and analog I/O signals of system components, engineers of all disciplines can now test new systems in realistic environments to evaluate their function and performance prior to field deployment. Within the Aerospace industry, space-borne satellite systems are arguably some of the most demanding in terms of their requirement for custom engineering and testing. Typically, spacecraft are built one or few at a time to fulfill a space science or defense mission. In contrast to other industries that can amortize the cost of HIL systems over thousands, even millions of units, spacecraft HIL systems have been built as one-of-a-kind solutions, expensive in terms of schedule, cost, and risk, to assure satellite and spacecraft systems reliability. The focus of this paper is to present a new approach to HIL testing for spacecraft systems that takes advantage of a highly flexible hardware/software architecture based on National Instruments PXI reconfigurable hardware and virtual instruments developed using LabVIEW. This new approach to HIL is based on a multistage/multimode spacecraft bus emulation development model called Reconfigurable Hardware In-the-Loop or RHIL.

Source record↗

Growing the success of Small Satellite missions through community learning

The successful utilization of small satellites for scientific missions relies on continual infusion of technology innovations, creative approaches, and new capabilities, all of which advance at a very rapid pace. Achieving these advancements requires open and efficient exchange of results, experiences, and ideas. Community learning is particularly challenging in this fast-growing community involving an increasingly diverse set of players from all sectors: industry, academia, government, and the public at large. Building and cultivating a community of practices around small satellite technology development and mission implementation are key objectives for NASA’s Small Spacecraft Systems Virtual Institute (S3VI). The institute has developed and provides access to a large collection of products, tools, and activities to advance clear communications and coordination regarding small spacecraft undertakings across NASA, to provide mission enabling information to the smallsat research community, to engage with stakeholders in industry, government, academia and the general public, and to support the overall small spacecraft community. New and updated offerings by the S3VI include: The2021 NASA State of the Art Report of Small Spacecraft Technology, the Small Spacecraft Reliability Initiative Knowledge Base, and the “MISSION ACCOMPLISHED”webinar series. These and other institute products will help scientists and engineers planning future missions answer pertinent questions, such as: What is the state of the art of small spacecraft technology that can be used?What are some best practices that other experts and teams can recommend? What did previous missions accomplish? What lessons could be learned from previous missions? What flight-proven parts are available? What emerging technologies could be taken advantage of? A status will be presented on S3VI activities facilitating community learning within the small satellite science community through the collection, sharing, and exchange of experiences with small satellite mission development and execution across all NASA mission areas.

Moretto Jorgensen, T↗

Growing the Success of Small Satellite Missions Through Community Learning

The successful utilization of small satellites for scientific missions relies on continual infusion of technology innovations, creative approaches, and new capabilities, all of which advance at a very rapid pace. Achieving these advancements requires open and efficient exchange of results, experiences, and ideas. Community learning is particularly challenging in this fast-growing community involving an increasingly diverse set of players from all sectors: industry, academia, government, and the public at large. Building and cultivating a community of practices around small satellite technology development and mission implementation are key objectives for NASA’s Small Spacecraft Systems Virtual Institute (S3VI). The institute has developed and provides access to a large collection of products, tools, and activities to advance clear communications and coordination regarding small spacecraft undertakings across NASA, to provide mission enabling information to the smallsat research community, to engage with stakeholders in industry, government, academia and the general public, and to support the overall small spacecraft community. New and updated offerings by the S3VI include: The2021 NASA State of the Art Report of Small Spacecraft Technology, the Small Spacecraft Reliability Initiative Knowledge Base, and the “MISSION ACCOMPLISHED” webinar series. These and other institute products will help scientists and engineers planning future missions answer pertinent questions, such as: What is the state of the art of small spacecraft technology that can be used? What are some best practices that other experts and teams can recommend? What did previous missions accomplish? What lessons could be learned from previous missions? What flight-proven parts are available? What emerging technologies could be taken advantage of? A status will be presented on S3VI activities facilitating community learning within the small satellite science community through the collection, sharing, and exchange of experiences with small satellite mission development and execution across all NASA mission areas.

Small Satellite↗

Miniaturized Autonomous Extravehicular Robotic Camera (Mini AERCam)

The NASA Johnson Space Center (JSC) Engineering Directorate is developing the Autonomous Extravehicular Robotic Camera (AERCam), a low-volume, low-mass free-flying camera system . AERCam project team personnel recently initiated development of a miniaturized version of AERCam known as Mini AERCam. The Mini AERCam target design is a spherical "nanosatellite" free-flyer 7.5 inches in diameter and weighing 1 0 pounds. Mini AERCam is building on the success of the AERCam Sprint STS-87 flight experiment by adding new on-board sensing and processing capabilities while simultaneously reducing volume by 80%. Achieving enhanced capability in a smaller package depends on applying miniaturization technology across virtually all subsystems. Technology innovations being incorporated include micro electromechanical system (MEMS) gyros, "camera-on-a-chip" CMOS imagers, rechargeable xenon gas propulsion system , rechargeable lithium ion battery, custom avionics based on the PowerPC 740 microprocessor, GPS relative navigation, digital radio frequency communications and tracking, micropatch antennas, digital instrumentation, and dense mechanical packaging. The Mini AERCam free-flyer will initially be integrated into an approximate flight-like configuration for demonstration on an airbearing table. A pilot-in-the-loop and hardware-in-the-loop simulation to simulate on-orbit navigation and dynamics will complement the airbearing table demonstration. The Mini AERCam lab demonstration is intended to form the basis for future development of an AERCam flight system that provides beneficial on-orbit views unobtainable from fixed cameras, cameras on robotic manipulators, or cameras carried by EVA crewmembers.

Fredrickson, Steven E.↗

COSMIC DAWN: Distributed Analysis of Wireless at Nextscale

Distributed Analysis of Wireless at Nextscale (DAWN) is a novel simulation framework for large-scale design-space exploration (DSE) of unmodified software-defined radio (SDR) applications interacting in a scalable, high-fidelity, virtual physics environment. The software-defined nature of the coupled software-physics simulation leverages hardware emulation to permit in-depth examination and modification of not only the electromagnetic environment, including each signal in flight, but also the precise state of system software and components. DAWN supports modular, customizable physics environments allowing realistic propagation effects so that computationally efficient empirical models, reduced order/surrogate models, or large-scale, high-fidelity, site-specific simulations can be used as a propagation medium based on scenario requirements. This paper introduces DAWN’s design and initial implementation, detailing key architectural components, including the Physics Realization Engine (PhyRE), Runtime Infrastructure for Simulation Environments (RISE), and the design space exploration (DSE) suite. It concludes with demonstrations using unmodified 4G/LTE software available from srsRAN on computing resources ranging from a small cluster to ORNL’s Frontier Exascale system.

Wise, Mike [ORNL] (ORCID:0000000266120641)↗

Flight Performance Handbook for Orbital Operations: Orbital Mechanics and Astrodynamics Formulae, Theorems, Techniques, and Applications

This handbook provides parametric data useful both to the space vehicle designer and mission analyst. It provides numerical and analytical relationships between missions and gross vehicle characteristics as a function of performance parameters. The effects of missile constraints and gross guidance limitations plus operational constraints such as launch site location, tracking net location, orbit visibility and mission on trajectory and orbit design parameters are exhibited. The influence of state-of- the-art applications of solar power as compared to future applications of nuclear power on orbit design parameters, such as eclipse time, are among the parameters included in the study. The principal aim, however, is in providing the analyst with useful parametric design information to cover the general area of earth satellite missions in the region of near-earth to cislunar space and beyond and from injection to atmospheric entry and controlled descent. The chapters are organized around the central idea of orbital operations in the 1961-1969 era with emphasis on parametric flight mechanics studies for ascent phase and parking orbits, transfer maneuvers, rendezvous maneuver, operational orbit considerations, and operational orbit control. The results are based almost entirely on the principles of flight and celestial mechanics. Numerous practical examples have been worked out in detail. This is especially important where it has been difficult or impossible to represent all possible variations of the parameters. The handbook contains analytical formulae and sufficient textual material to permit their proper use. The analytic methods consist of both exact and rapid, approximate methods. Scores of tables, working graphs and illustrations amplify the mathematical models which, together with important facts and data, cover the engineering and scientific applications of orbital mechanics. Each of the five major chapters are arranged to provide a rapid review of an entire astrodynamic subject. By the use of compact graphical and tabular presentation the full scope of the material is made available in an easy-to-use style. Throughout the volume the analyst is shown, by means of suitable introductions, notes, authoritative examples, and cross-references the vital interrelation of the various orbital mechanics topics in the general field of earth satellites and satellite rendezvous. The handbook is designed to give the analyst rapid, reliable access to the mathematics of orbital mechanics needed for virtually any working requirements.

Ambrosio, Alphonso↗

An Application-Based Performance Evaluation of NASAs Nebula Cloud Computing Platform

The high performance computing (HPC) community has shown tremendous interest in exploring cloud computing as it promises high potential. In this paper, we examine the feasibility, performance, and scalability of production quality scientific and engineering applications of interest to NASA on NASA's cloud computing platform, called Nebula, hosted at Ames Research Center. This work represents the comprehensive evaluation of Nebula using NUTTCP, HPCC, NPB, I/O, and MPI function benchmarks as well as four applications representative of the NASA HPC workload. Specifically, we compare Nebula performance on some of these benchmarks and applications to that of NASA s Pleiades supercomputer, a traditional HPC system. We also investigate the impact of virtIO and jumbo frames on interconnect performance. Overall results indicate that on Nebula (i) virtIO and jumbo frames improve network bandwidth by a factor of 5x, (ii) there is a significant virtualization layer overhead of about 10% to 25%, (iii) write performance is lower by a factor of 25x, (iv) latency for short MPI messages is very high, and (v) overall performance is 15% to 48% lower than that on Pleiades for NASA HPC applications. We also comment on the usability of the cloud platform.

Saini, Subhash↗

Virtual Inspection of Advanced Manufacturing via Process-Scale Digital Twins (Abbreviated Report)

Inspection and certification comprise the most significant bottlenecks in advanced manufacturing for NNSA applications, often requiring far more time and resources than the fabrication of the parts themselves. Traditional methods, such as manual review and X-ray computed tomography, are not only slow and costly, but also struggle to provide a clear connection between manufacturing instructions and the final performance of critical components. This gap limits both the agility and assurance needed to support the modernization and safety of the United States nuclear stockpile. In response, our Strategic Initiative established a digital twin framework that integrates realtime process monitoring, automated data analysis, and immersive virtual reality collaboration into a unified inspection pipeline. By leveraging data from sensors, machine instructions, and imaging, we created high-fidelity virtual models of manufactured parts that could be rapidly analyzed and certified. This approach was first demonstrated with Direct Ink Write, and then extended to other manufacturing settings, including conventional (or “subtractive”) manufacturing and to predict the end of life performance of parts per the aging and lifetimes programs. The result is a transformational capability: inspection times have been reduced by a factor of 120,000 without loss of accuracy and while simultaneously improving traceability and confidence in part quality. This framework not only streamlines certification for critical applications, but also positions the national security enterprise to respond more flexibly to emerging challenges, supporting agile manufacturing and digital engineering practices across a broad range of mission-relevant domains.

42 ENGINEERING↗

Planetary Suit Hip Bearing Model for Predicting Design vs. Performance

Designing a planetary suit is very complex and often requires difficult trade-offs between performance, cost, mass, and system complexity. In order to verifying that new suit designs meet requirements, full prototypes must eventually be built and tested with human subjects. Using computer models early in the design phase of new hardware development can be advantageous, allowing virtual prototyping to take place. Having easily modifiable models of the suit hard sections may reduce the time it takes to make changes to the hardware designs and then to understand their impact on suit and human performance. A virtual design environment gives designers the ability to think outside the box and exhaust design possibilities before building and testing physical prototypes with human subjects. Reductions in prototyping and testing may eventually reduce development costs. This study is an attempt to develop computer models of the hard components of the suit with known physical characteristics, supplemented with human subject performance data. Objectives: The primary objective was to develop an articulating solid model of the Mark III hip bearings to be used for evaluating suit design performance of the hip joint. Methods: Solid models of a planetary prototype (Mark III) suit s hip bearings and brief section were reverse-engineered from the prototype. The performance of the models was then compared by evaluating the mobility performance differences between the nominal hardware configuration and hardware modifications. This was accomplished by gathering data from specific suited tasks. Subjects performed maximum flexion and abduction tasks while in a nominal suit bearing configuration and in three off-nominal configurations. Performance data for the hip were recorded using state-of-the-art motion capture technology. Results: The results demonstrate that solid models of planetary suit hard segments for use as a performance design tool is feasible. From a general trend perspective, the suited performance trends were comparable between the model and the suited subjects. With the three off-nominal bearing configurations compared to the nominal bearing configurations, human subjects showed decreases in hip flexion of 64%, 6%, and 13% and in hip abduction of 59%, 2%, and 20%. Likewise the solid model showed decreases in hip flexion of 58%, 1%, and 25% and in hip abduction of 56%, 0%, and 30%, under the same condition changes from the nominal configuration. Differences seen between the model predictions and the human subject performance data could be attributed to the model lacking dynamic elements and performing kinematic analysis only, the level of fit of the subjects with the suit, the levels of the subject s suit experience.

Cowley, Matthew S.↗