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NASA NTRS2010

Abrasion Testing of Candidate Outer Layer Fabrics for Lunar EVA Space Suits

During the Apollo program, the space suit outer layer fabrics were badly abraded after just a few Extravehicular Activities (EVAs). For example, the Apollo 12 commander reported abrasive wear on the boots, which penetrated the outer layer fabric into the thermal protection layers after less than eight hours of surface operations. Current plans for the Constellation Space Suit Element require the space suits to support hundreds of hours of EVA on the Lunar surface, creating a challenge for space suit designers to utilize materials advances made over the last forty years and improve upon the space suit fabrics used in the Apollo program. A test methodology has been developed by the NASA Johnson Space Center Crew and Thermal Systems Division for establishing comparative abrasion wear characteristics between various candidate space suit outer layer fabrics. The abrasion test method incorporates a large rotary drum tumbler with rocks and loose lunar simulant material to induce abrasion in fabric test cylinder elements, representative of what might occur during long term planetary surface EVAs. Preliminary materials screening activities were conducted to determine the degree of wear on representative space suit outer layer materials and the corresponding dust permeation encountered between subsequent sub -layers of thermal protective materials when exposed to a simulated worst case eight hour EVA. The test method was used to provide a preliminary evaluation of four candidate outer layer fabrics for future planetary surface space suit applications. This Paper provides a review of previous abrasion studies on space suit fabrics, details the methodologies used for abrasion testing in this particular study, and shares the results and conclusions of the testing.

Mitchell, Kathryn C.↗

NASA NTRS2005

Modifications of Fabrication of Vibratory Microgyroscopes

A micromachining process for the fabrication of vibratory microgyroscopes from silicon wafers, and aspects of the microgyroscope design that are inextricably linked with the fabrication process, have been modified in an effort to increase production yields from perspectives of both quantity and quality. Prior to the modifications, the effective production yield of working microgyroscopes was limited to one or less per wafer. The modifications are part of a continuing effort to improve the design and increase production yields to more than 30 working microgyroscopes per wafer. A discussion of pertinent aspects of the unmodified design and the unmodified fabrication process is prerequisite to a meaningful description of the modifications. The design of the microgyroscope package was not conducive to high yield and rapid testing of many microgyroscopes. One of the major impediments to high yield and testing was found to lie in vibration- isolation beams around the four edges of each microgyroscope, which beams were found to be unnecessary for achieving high resonance quality factors (Q values) characterizing the vibrations of petallike cantilevers. The fabrication process included an 8- m-deep plasma etch. The purpose of the etch was to create 8- m vertical gaps, below which were to be placed large gold evaporated electrodes and sensing pads to drive and sense resonant vibrations of the "petals." The process also included a step in which bridges between dies were cut to separate the dies. The etched areas must be kept clean and smooth (free of debris and spikes), because any object close to 8 m high in those areas would stop the vibrations. However, it was found that after the etch, there remained some spikes with heights that were, variously, almost as high or as high as the etch depth. It also was found that the cutting of bridges created silicon debris, some of which lodged in the 8- m gaps and some of which landed on top of the petals. The masses added to the petals by the debris altered resonance frequencies and/or Q values to unacceptable degrees. Hence, the spikes and the debris have been conjectured to cause most of the observed malfunctions of newly fabricated microgyroscopes. Another pertinent aspect of the unmodified design and process was the fabrication of electrodes and the 8- m capacitance gap on a 500- m-thick wafer, and the fabrication of a 3-mm-thick baseplate from another wafer. It was necessary to bond these wafers to each other in an assembly step that was later found to be superfluous in that it could be eliminated by a suitable modification of the design.

Bae, Sam Y.↗

NASA NTRS2016

Additive Manufacturing, Design, Testing, and Fabrication: A Full Engineering Experience at JSC

I worked on several projects this term. While most projects involved additive manufacturing, I was also involved with two design projects, two testing projects, and a fabrication project. The primary mentor for these was Richard Hagen. Secondary mentors were Hai Nguyen, Khadijah Shariff, and fabrication training from James Brown. Overall, my experience at JSC has been successful and what I have learned will continue to help me in my engineering education and profession long after I leave. My 3D printing projects ranged from less than a 1 cubic centimeter to about 1 cubic foot and involved several printers using different printing technologies. It was exciting to become familiar with printing technologies such as industrial grade FDM (Fused Deposition Modeling), the relatively new SLA (Stereolithography), and PolyJet. My primary duty with the FDM printers was to model parts that came in from various sources to print effectively and efficiently. Using methods my mentor taught me and the Stratasys Insight software, I was able to minimize imperfections, hasten build time, improve strength for specific forces (tensile, shear, etc...), and reduce likelihood of a print-failure. Also using FDM, I learned how to repair a part after it was printed. This is done by using a special kind of glue that chemically melts the two faces of plastic parts together to form a fused interface. My first goal with SLA technology was to bring the printer back to operational readiness. In becoming familiar with the Pegasus SLA printer, I researched the leveling, laser settings, and different vats to hold liquid material. With this research, I was successfully able to bring the Pegasus back online and have successfully printed multiple sample parts as well as functional parts. My experience with PolyJet technology has been focused on an understanding of the abilities/limits, costs, and the maintenance for daily use. Still upcoming will be experience with using a composite printer that uses FDM technology to print plastic while laying an internal filament of Kevlar or carbon-fiber inside the printed material. It has been incredible being exposed to this range of technologies and I feel very fortunate to be ready for virtually any kind of printing technology I come across in the future. Design work played a part in my internship this term as well. Working with Hai Nguyen, I was able to design a set of testing tips and a test frame for use with an Arcjet. The testing tips will be made of several different materials that will possibly be used in the heat shield of the Orion space craft. These designs included technical drawings that were presented to the fabrication shop. The frame design was created from 80/20 (a popular brand of frame construction equipment) and included an order form with pricing for fabrication. An independent design was also done for the virtual reality lab. This design was to create a hand-controller based on a previous design. This final design was sent directly to a 3D printer without technical drawings. Overall, my design work has given me experience with using 80/20, helped improve my CAD (Computer Aided Design) proficiency, and increased my knowledge of how to set up technical drawings for fabrication. The final role I have played in this internship has been to assist with testing of the inflatable technology materials working Khadijah Shariff. I began the internship assisting with permeability testing with the initial plan to continue the testing independently after training. Unfortunately, the testing apparatus suffered a technical failure and had funding pulled which cancelled that portion of the project. Further testing with inflatable technology continued with tensile testing of various stitching methods. This testing took place over a two-days and concluded successfully. Final testing was to be more tensile testing but of straps used to connect various inflatable sections. Unfortunately, the needed grips for the tensile tests could not be located and put the testing on hold. It is possible this round of testing will still take place by the end of the internship if the grips can be found. Overall, this portion of the internship has helped me become familiar with one kind of permeability test as well as a popular tensile/compression testing machine. Finally, I also had the chance to be trained using a metal lathe for making very small tips for a soldering iron. These tips will be used to melt threaded brass inserts into 3D printed plastic. Working with James Brown, I was able to successfully machine a brass rod down to as little as 0.064 inches plus or minus 0.001 inches. It was very rewarding to learn how to best use the machine and become familiar with a skill that will undoubtedly be used again in the future. I have been told by several professional engineers that learning to use a lathe and mill will be invaluable skills in the field. This knocks 50 percent of that goal off and I look forward to learning the mill at some point in the future. As is apparent with this list of projects, my internship was not focused on a single over-arching goal. Instead, I was able to gain experience in a myriad of very different areas. I feel like my time here was spent bouncing from one project to the next. Though sometimes difficult to switch gears, it was very rewarding to be a part of so much in so little time. My career and education will be positively impacted by what I have learned at JSC. My experience with 3D printing has improved my ability to handle many issues that may come up in the future with multiple different technologies. The design work I took part in, especially creating technical drawings, will help me better present designs to any engineer or shop I will encounter. My testing experience has helped me become familiar with a popular kind of tensile test machine that will likely be similar to the kinds I will encounter in the future. Finally, my experience with fabrication has given me a rare opportunity, as an engineer, to take part in the fabrication of a part. This experience will help me better tailor my future designs for the manufacturing process and has given me an appreciation for detailed/delicate machining work. My experience at JSC has been successful and will continue to assist me for a long time within the engineering field.

Zusack, Steven↗

NASA NTRS2017

Fabrication of the HIAD Large-Scale Demonstration Assembly and Upcoming Mission Applications

Over a decade of work has been conducted in the development of NASAs Hypersonic Inflatable Aerodynamic Decelerator (HIAD) technology. This effort has included multiple ground test campaigns and flight tests culminating in the HIAD projects second generation (Gen-2) deployable aeroshell system and associated analytical tools. NASAs HIAD project team has developed, fabricated, and tested inflatable structures (IS) integrated with flexible thermal protection system (F-TPS), ranging in diameters from 3-6m, with cone angles of 60 and 70 deg.In 2015, United Launch Alliance (ULA) announced that they will use a HIAD (10-12m) as part of their Sensible, Modular, Autonomous Return Technology (SMART) for their upcoming Vulcan rocket. ULA expects SMART reusability, coupled with other advancements for Vulcan, will substantially reduce the cost of access to space. The first booster engine recovery via HIAD is scheduled for 2024. To meet this near-term need, as well as future NASA applications, the HIAD team is investigating taking the technology to the 10-15m diameter scale.In the last year, many significant development and fabrication efforts have been accomplished, culminating in the construction of a large-scale inflatable structure demonstration assembly. This assembly incorporated the first three tori for a 12m Mars Human-Scale Pathfinder HIAD conceptual design that was constructed with the current state of the art material set. Numerous design trades and torus fabrication demonstrations preceded this effort. In 2016, three large-scale tori (0.61m cross-section) and six subscale tori (0.25m cross-section) were manufactured to demonstrate fabrication techniques using the newest candidate material sets. These tori were tested to evaluate durability and load capacity. This work led to the selection of the inflatable structures third generation (Gen-3) structural liner. In late 2016, the three tori required for the large-scale demonstration assembly were fabricated, and then integrated in early 2017. The design includes provisions to add the remaining four tori necessary to complete the assembly of the 12m Human-Scale Pathfinder HIAD in the event future project funding becomes available.This presentation will discuss the HIAD large-scale demonstration assembly design and fabrication per-formed in the last year including the precursor tori development and the partial-stack fabrication. Potential near-term and future 10-15m HIAD applications will also be discussed.

Swanson, G. T.↗

NASA NTRS2017

Fabrication of the HIAD Large-Scale Demonstration Assembly

Over a decade of work has been conducted in the development of NASA's Hypersonic Inflatable Aerodynamic Decelerator (HIAD) technology. This effort has included multiple ground test campaigns and flight tests culminating in the HIAD projects second generation (Gen-2) deployable aeroshell system and associated analytical tools. NASAs HIAD project team has developed, fabricated, and tested inflatable structures (IS) integrated with flexible thermal protection system (F-TPS), ranging in diameters from 3-6m, with cone angles of 60 and 70 deg.In 2015, United Launch Alliance (ULA) announced that they will use a HIAD (10-12m) as part of their Sensible, Modular, Autonomous Return Technology (SMART) for their upcoming Vulcan rocket. ULA expects SMART reusability, coupled with other advancements for Vulcan, will substantially reduce the cost of access to space. The first booster engine recovery via HIAD is scheduled for 2024. To meet this near-term need, as well as future NASA applications, the HIAD team is investigating taking the technology to the 10-15m diameter scale. In the last year, many significant development and fabrication efforts have been accomplished, culminating in the construction of a large-scale inflatable structure demonstration assembly. This assembly incorporated the first three tori for a 12m Mars Human-Scale Pathfinder HIAD conceptual design that was constructed with the current state of the art material set. Numerous design trades and torus fabrication demonstrations preceded this effort. In 2016, three large-scale tori (0.61m cross-section) and six subscale tori (0.25m cross-section) were manufactured to demonstrate fabrication techniques using the newest candidate material sets. These tori were tested to evaluate durability and load capacity. This work led to the selection of the inflatable structures third generation (Gen-3) structural liner. In late 2016, the three tori required for the large-scale demonstration assembly were fabricated, and then integrated in early 2017. The design includes provisions to add the remaining four tori necessary to complete the assembly of the 12m Human-Scale Pathfinder HIAD in the event future project funding becomes available.This presentation will discuss the HIAD large-scale demonstration assembly design and fabrication per-formed in the last year including the precursor tori development and the partial-stack fabrication. Potential near-term and future 10-15m HIAD applications will also be discussed.

Swanson, G. T.↗

NASA NTRS2018

Permeability of a New Parachute Fabric – Measurements, Modeling, and Application

In response to a NASA request, Heathcoat Fabrics Limited has woven a new parachute fabric (Custom Design 1 G-60315-1800-Q01). This fabric was tested to obtain its permeability in air (i.e., flow-through volume of air per area per time) over a range of differential pressures from 0.146 to 25 psf (7 to 1197 Pa). The fabric met its specification permeability of 60 to 100 ft3/ft2/min (30.5 to 50.8 cm3/cm2/s) at the U.S. standard differential pressure of 0.5 inch of water (2.60 psf, 124 Pa). The permeability results were transformed into an effective porosity model for use in calculations related to the total porosity of parachutes. The tested fabric is being considered for use in parachutes for future missions to Mars. Calculations of drag coefficient were performed for two geometrically identical parachutes using either the new fabric or fabric woven to Parachute Industry Specification PIA-C-7020D Type I (Mars Science Laboratory Disk-Gap-Band parachute operating on Mars at a Mach number of 0.41). These calculations indicate essentially no difference in the drag coefficient between the two parachutes.

Cruz, Juan R.↗

NASA NTRS2026

Artemis Suit Material Optical Property Testing of Dust Exposed Fabrics

This paper highlights one aspect of NASA’s ongoing technology-infusion effort to design, fabricate, and test a next-generation outer shell fabric for a lunar Extravehicular Activity (EVA) space suit, a critical component of sustained lunar exploration. Managing thermal loads on the Moon is essential for astronaut safety and suit performance. The suit’s exterior fabric directly influences heat gain and loss through its optical properties: low solar absorptivity minimizes sunlight absorption, while high infrared emissivity aids radiative cooling. Lunar regolith complicates this balance. Its fine, abrasive particles possess unique optical behavior that can lower reflectivity and raise emissivity when embedded in or adhered to fabric surfaces, degrading thermal control and increasing the risk of overheating or cooling inefficiency. To quantify these effects, the Artemis Suit Materials (ASM) team measured solar absorptance and infrared emissivity of clean and dust-soiled Ortho Fabric, establishing beginning-of-life (BOL) and end-of-life (EOL) benchmarks. EOL conditions were simulated with a rotary tumbler abrasion process using lunar dust simulant and ceramic media to reproduce cumulative wear expected during surface operations. Tests also included unmodified fabrics and a fabric/film laminate system containing titanium dioxide to evaluate potential improvements in dust resistance and optical performance. Results from these evaluations provide critical insight into how lunar dust alters fabric thermal behavior and inform the design of bespoke suit materials that maintain required optical properties throughout mission life, supporting safe and effective long-duration EVA on the lunar surface.

space↗

NASA NTRS2026

Artemis Suit Material Optical Property Testing of Dust Exposed Fabrics

Textile↗

NASA NTRS1976

Advanced composites: Fabrication processes for selected resin matrix materials

This design note is based on present state of the art for epoxy and polyimide matrix composite fabrication technology. Boron/epoxy and polyimide and graphite/epoxy and polyimide structural parts can be successfully fabricated. Fabrication cycles for polyimide matrix composites have been shortened to near epoxy cycle times. Nondestructive testing has proven useful in detecting defects and anomalies in composite structure elements. Fabrication methods and tooling materials are discussed along with the advantages and disadvantages of different tooling materials. Types of honeycomb core, material costs and fabrication methods are shown in table form for comparison. Fabrication limits based on tooling size, pressure capabilities and various machining operations are also discussed.

Welhart, E. K.↗

NASA NTRS1986

Optical properties of woven ceramic fabrics for flexible heat shields

Optical-properties data for ceramic fabrics woven from silica, aluminoborosilicate, or silicon carbide yarns are presented. The normal hemispheric reflectances and transmittances measured at room temperature and over the spectral range of 250 to 2500 nm show a large dependence on fabric weight and a lesser dependence on fabric weave pattern. Reflectances of silicon carbide fabrics are lower by a factor of about 10 than those of silica and aluminoborosilicate. The reflectance and transmittance of silica and aluminoborosilicate fabrics decrease at wavelengths below 500 nm because of material absorption. A two-flux analytical model is used to derive spectral absorption and scattering coefficients for the silica and aluminoborosilicate fabrics from the measured reflectance and transmittance data, and comparisons are made with available data for other ceramics.

Covington, M. A.↗

NASA NTRS1988

Low cost damage tolerant composite fabrication

The resin transfer molding (RTM) process applied to composite aircraft parts offers the potential for using low cost resin systems with dry graphite fabrics that can be significantly less expensive than prepreg tape fabricated components. Stitched graphite fabric composites have demonstrated compression after impact failure performance that equals or exceeds that of thermoplastic or tough thermoset matrix composites. This paper reviews methods developed to fabricate complex shape composite parts using stitched graphite fabrics to increase damage tolerance with RTM processes to reduce fabrication cost.

Palmer, R. J.↗

NASA NTRS1992

Fabrication

What aspects of optical fabrication technology need to be developed so as to facilitate existing planned missions, or enable new ones? Throughout the submillimeter to UV wavelengths, the common goal is to push technology to the limits to make the largest possible apertures that are diffraction limited. At any one wavelength, the accuracy of the surface must be better than lambda/30 (rms error). The wavelength range is huge, covering four orders of magnitude from 1 mm to 100 nm. At the longer wavelengths, diffraction limited surfaces can be shaped with relatively crude techniques. The challenge in their fabrication is to make as large as possible a reflector, given the weight and volume constraints of the launch vehicle. The limited cargo diameter of the shuttle has led in the past to emphasis on deployable or erectable concepts such as the Large Deployable Reflector (LDR), which was studied by NASA for a submillimeter astrophysics mission. Replication techniques that can be used to produce light, low-cost reflecting panels are of great interest for this class of mission. At shorter wavelengths, in the optical and ultraviolet, optical fabrication will tax to the limit the most refined polishing methods. Methods of mechanical and thermal stabilization of the substrate will be severely stressed. In the thermal infrared, the need for large aperture is tempered by the even stronger need to control the telescope's thermal emission by cooled or cryogenic operation. Thus, the SIRTF mirror at 1 meter is not large and does not require unusually high accuracy, but the fabrication process must produce a mirror that is the right shape at a temperature of 4 K. Future large cooled mirrors will present more severe problems, especially if they must also be accurate enough to work at optical wavelengths. At the very shortest wavelengths accessible to reflecting optics, in the x-ray domain, the very low count fluxes of high energy photons place a premium on the collecting area. It is not necessary to reach or even approach the diffraction limit, which would demand subnanometer fabrication and figure control. Replication techniques that produce large very lightweight surfaces are of interest for x-ray optics just as they are for the submillimeter region. Optical fabrication requirements are examined in more detail for missions in each of the three spectral regions of interest in astrophysics.

Angel, Roger↗

NASA NTRS1999

Fabrication of Pop-up Detector Arrays on Si Wafers

High sensitivity is a basic requirement for a new generation of thermal detectors. To meet the requirement, close-packed, two-dimensional silicon detector arrays have been developed in NASA Goddard Space Flight Center. The goal of the task is to fabricate detector arrays configured with thermal detectors such as infrared bolometers and x-ray calorimeters to use in space fliGht missions. This paper focuses on the fabrication and the mechanical testing of detector arrays in a 0.2 mm pixel size, the smallest pop-up detectors being developed so far. These array structures, nicknamed "PUDS" for "Pop-Up Detectors", are fabricated on I pm thick, single-crystal, silicon membranes. Their designs have been refined so we can utilize the flexibility of thin silicon films by actually folding the silicon membranes to 90 degrees in order to obtain close-packed two-dimensional arrays. The PUD elements consist of a detector platform and two legs for mechanical support while also serving as electrical and thermal paths. Torsion bars and cantilevers connecting the detector platform to the legs provide additional flexures for strain relief. Using micro-electromechanical structure (MEMS) fabrication techniques, including photolithography, anisotropic chemical etching, reactive-ion etching, and laser dicing, we have fabricated PLTD detector arrays of fourteen designs with a variation of four parameters including cantilever length, torsion bar length and width, and leg length. Folding tests were conducted to test mechanical stress distribution for the array structures. We obtained folding yields and selected optimum design parameters to reach minimal stress levels. Computer simulation was also employed to verify mechanical behaviors of PUDs in the folding process. In addition, scanning electron microscopy was utilized to examine the flatness of detectors and the alignment of detector pixels in arrays. The fabrication of thermistors and heaters on the pop-up detectors is under way, preparing us for the next step of the experiment, the thermal test.

Li, Mary J.↗

NASA NTRS2004

Stirling Microregenerators Fabricated and Tested

A mesoscale Stirling refrigerator patented by the NASA Glenn Research Center is currently under development. This refrigerator has a predicted efficiency of 30 percent of Carnot and potential uses in electronics, sensors, optical and radiofrequency systems, microarrays, and microsystems. The mesoscale Stirling refrigerator is most suited to volume-limited applications that require cooling below the ambient or sink temperature. Primary components of the planar device include two diaphragm actuators that replace the pistons found in traditional-scale Stirling machines and a microregenerator that stores and releases thermal energy to the working gas during the Stirling cycle. Diaphragms are used to eliminate frictional losses and bypass leakage concerns associated with pistons, while permitting reversal of the hot and cold sides of the device during operation to allow precise temperature control. Three candidate microregenerators were fabricated under NASA grants for initial evaluation: two constructed of porous ceramic, which were fabricated by Johns Hopkins Applied Physics Laboratory, and one made of multiple layers of nickel and photoresist, which was fabricated by Polar Thermal Technologies. The candidate regenerators are being tested by Johns Hopkins Applied Physics in a custom piezoelectric-actuated test apparatus designed to produce the Stirling refrigeration cycle. In parallel with the regenerator testing, Johns Hopkins is using deep reactive ion etching to fabricate electrostatically driven, comb-drive diaphragm actuators. These actuators will drive the Stirling cycle in the prototype device. The top photograph shows the porous ceramic microregenerators. Two microregenerators were fabricated with coarse pores and two with fine pores. The bottom photograph shows the test apparatus parts for evaluating the microregenerators, including the layered nickel-and-photoresist regenerator fabricated using LIGA techniques.

Moran, Matthew E.↗

NASA NTRS2002

Excellent Ballistic Impact Properties Demonstrated By New Fabric

Recently, a relatively new industrial fiber known by the trade name Zylon has been under commercial development by Toyobo Co., Ltd., Japan. In ballistic impact tests conducted at the NASA Glenn Research Center, it was found that dry fabric braided of Zylon had greater ballistic impact capacity than comparable (braid style and weight) fabric braided of Kevlar. To study the potential use of Zylon fabric in jet engine containment systems, the fabric was tested in Glenn's Structures and Acoustics Division Ballistic Impact Facility under conditions simulating those which occur in a jet engine blade-out event. Circular ring test specimens were fabricated by wrapping five layers of braided Zylon or Kevlar fabric around an inner ring made of a thin sheet of aluminum and a 1-in.-thick layer of aluminum honeycomb. The test specimens had an inner diameter of 40 in., an axial length of 10 in., and a wall thickness of approximately 1.5in. A test specimen is shown in the photograph.

Pereira, J. Michael↗

NASA NTRS2006

Developing Fabrication Technologies to Provide On Demand Manufacturing for Exploration of the Moon and Mars

NASA's human exploration initiative poses great opportunity and risk for manned and robotic missions to the Moon, Mars, and beyond. Engineers and scientists at the Marshall Space Flight Center (MSFC) are developing technologies for in situ fabrication capabilities during lunar and Martian surface operations utilizing provisioned and locally refined materials. Current fabrication technologies must be advanced to support the special demands and applications of the space exploration initiative such as power, weight and volume constraints. In Situ Fabrication and Repair (ISFR) will advance state-of-the-art technologies in support of habitat structure development, tools, and mechanical part fabrication. The repair and replacement of space mission components, such as life support items or crew exercise equipment, fall within the ISFR scope. This paper will address current fabrication technologies relative to meeting ISFR targeted capabilities, near-term advancement goals, and systematic evaluation of various fabrication methods.

Hammond, Monica S.↗

NASA NTRS2008

From Lunar Regolith to Fabricated Parts: Technology Developments and the Utilization of Moon Dirt

The U.S. Space Exploration Policy has as a cornerstone the establishment of an outpost on the moon. This lunar outpost wil1 eventually provide the necessary planning, technology development, testbed, and training for manned missions in the future beyond the Moon. As part of the overall activity, the National Aeronautics and Space Administration (NASA) is investigating how the in situ resources can be utilized to improve mission success by reducing up-mass, improving safety, reducing risk, and bringing down costs for the overall mission. Marshall Space Flight Center (MSFC), along with other NASA centers, is supporting this endeavor by exploring how lunar regolith can be mined for uses such as construction, life support, propulsion, power, and fabrication. An infrastructure capable of fabrication and nondestructive evaluation will be needed to support habitat structure development and maintenance, tools and mechanical parts fabrication, as well as repair and replacement of space-mission hardware such as life-support items, vehicle components, and crew systems, This infrastructure will utilize the technologies being developed under the In Situ Fabrication and Repair (ISFR) element, which is working in conjunction with the technologies being developed under the In Situ Resources Utilization (ISRU) element, to live off the land. The ISFR Element supports the Space Exploration Initiative by reducing downtime due to failed components; decreasing risk to crew by recovering quickly from degraded operation of equipment; improving system functionality with advanced geometry capabilities; and enhancing mission safety by reducing assembly part counts of original designs where possible. This paper addresses the need and plan for understanding the properties of the lunar regolith to determine the applicability of using this material in a fabrication process. This effort includes the development of high fidelity simulants that will be used in fabrication processes on the ground to drive down risk and increase the Technology Readiness Level (TRL) prior to implementing this capability on the moon. Also discussed in this paper is the on-going research using Electron Beam Melting (EBM) technology as a possible solution to manufacturing parts and spares on the Moon's surface.

McLemore, C. A.↗

NASA NTRS2009

Fabricating Radial Groove Gratings Using Projection Photolithography

Projection photolithography has been used as a fabrication method for radial grove gratings. Use of photolithographic method for diffraction grating fabrication represents the most significant breakthrough in grating technology in the last 60 years, since the introduction of holographic written gratings. Unlike traditional methods utilized for grating fabrication, this method has the advantage of producing complex diffractive groove contours that can be designed at pixel-by-pixel level, with pixel size currently at the level of 45 45 nm. Typical placement accuracy of the grating pixels is 10 nm over 30 nm. It is far superior to holographic, mechanically ruled or direct e-beam written gratings and results in high spatial coherence and low spectral cross-talk. Due to the smooth surface produced by reactive ion etch, such gratings have a low level of randomly scattered light. Also, due to high fidelity and good surface roughness, this method is ideally suited for fabrication of radial groove gratings. The projection mask is created using a laser writer. A single crystal silicon wafer is coated with photoresist, and then the projection mask, with its layer of photoresist, is exposed for patterning in a stepper or scanner. To develop the photoresist, the fabricator either removes the exposed areas (positive resist) of the unexposed areas (negative resist). Next, the patterned and developed photoresist silicon substrate is subjected to reactive ion etching. After this step, the substrate is cleaned. The projection mask is fabricated according to electronic design files that may be generated in GDS file format using any suitable CAD (computer-aided design) or other software program. Radial groove gratings in off-axis grazing angle of incidence mount are of special interest for x-ray spectroscopy, as they allow achieving higher spectral resolution for the same grating area and have lower alignment tolerances than traditional in-plane grating scheme. This is especially critical for NASA Constellation- X project that will utilize hundreds of gratings all of which need to be precisely aligned for x-ray observation of space.

Iazikov, Dmitri↗