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NASA NTRS1978

A Roof for the Lion's House

Fans of the National Football League's Detroit Lions don't worry about gameday weather. Their magnificent new Pontiac Stadium has a domed, air-supported, fabric roof that admits light but protects the playing field and patrons from the elements. The 80,000-seat "Silverdome" is the world's largest fabric-covered structure-and aerospace technology played an important part in its construction. The key to economical construction of the Silverdome-and many other types of buildings-is a spinoff of fiber glass Beta yarn coated with Teflon TFE fluorocarbon resin. The big advance it offers is permanency. Fabric structures-tents, for example have been around since the earliest years of human civilization. But their coverings-hides, canvas and more recently plastics-were considered temporary; though tough, these fabrics were subject to weather deterioration. Teflon TFE-coated Beta Fiberglas is virtually impervious to the effects of weather and sunlight and it won't stretch, shrink, mildew or rot, thus has exceptional longevity; it is also very strong, lightweight, flame resistant and requires no periodic cleaning, because dirt will not stick to the surface of Teflon TFE. And to top all that, it costs only 30 to 40 percent as much as conventional roofing.

Source record↗

NASA NTRS1990

Technology needs of the Exploration Initiative

An overview of the U.S. Space Exploration Initiative (SEI) is presented. The two primary objectives of the initiative are a return to the moon to create a permanent lunar base and a human mission to Mars. Even though mission architectural concepts are not yet defined, previous studies indicate that the SEI will require developments in numerous areas, including advanced engines for space transportation, in-space assembly and construction to support permanent basing of exploration systems in space, and advanced surface operations capabilities including satisfactory levels of power and surface roving vehicles, and technologies to safely support human space operations of long duration. The process of mission definition has begun and it is shown that it is possible to identify a family of fundamental functional building blocks from which all SEI mission architectures will be constructed.

Aldrich, Arnold↗

DOE OSTI2025

Rapid data acquisition and machine learning-assisted composition design of functionally graded alloys via wire arc additive manufacturing

Abstract The lack of high-quality datasets in materials science hinders artificial intelligence (AI)-driven alloy design. To address this challenge, wire arc additive manufacturing (WAAM) was employed to fabricate graded alloys, generating extensive data for machine learning (ML)-assisted property prediction. ML models were developed using high-throughput experiments, computational models, and genetic algorithm to optimize feature selection, successfully predicting hardness and porosity. The ML model demonstrated its efficacy by designing a gradient alloy with enhanced properties. However, scaling up revealed uncertainties in tensile property and porosity due to differences in size and thermal conditions between the designed alloy build and the gradient print used to construct the ML model. This underscores the need for uncertainty quantification and process optimization in WAAM-driven alloy design. Our work advances AI-integrated additive manufacturing, offering a rapid approach to exploring process–structure–property relationships and accelerating materials development.

Wang, Xin↗

NASA NTRSDate not supplied

Lessons Learned From Designing and Building Low Organic Outgassing Cleanrooms for NASA OSIRIS-REx and Hayabusa2 Curation Facility

NASA Johnson Space Center Astromaterials Acquisition and Curation Office completed construction and commissioning of the OSIRIS-REx and Hayabusa2 cleanroom laboratory suites along with new precision cleaning and advanced curation laboratories consisting of ISO Class 5, 6, and 7 cleanrooms. The new curation facilities are designed for initial receiving, basic characterization, curation processing, and preliminary examination of carbonaceous asteroidal material. The facilities are also designed to enable long-term pristine sample storage to preserve the scientific integrity of each sample to enable future research by the international science community. The scientific study of organics is critical for both missions. The OSIRIS-REx mission instituted a stringent contamination control plan for low organics. Given these mission requirements and long-term storage preservation requirements, cleanroom construction materials were carefully selected to not hinder the scientific search for amino acids and the study of organics in the samples. Cleanroom candidate construction materials were researched for the HVAC system, floors, walls, ceiling, and plenum areas. The team chose several candidate materials that were further tested for their specific outgassing characteristics using ASTM E-595 per ASTM E-2312. The information gained provided the foundation for the final design selection of the cleanroom materials. While material selection is important before and during the facility design phase, the construction phase is where these choices are implemented by the prime construction contractor through final product and material submittals. These submittals are the last check point and changes are often submitted due to engineering/construction conflicts, especially when renovating an existing building. Any new material or equipment/product change must be identified and scrutinized for low particulate shedding and outgassing properties. In some cases, quick testing of new material is required, and compromises must be made in real-time. Careful selection and implementation of cleanroom materials significantly reduced organic and inorganic contamination beyond normal cleanroom baselines.

astromaterials curation↗

NASA NTRSDate not supplied

Lessons Learned From Designing and Building Low Organic Outgassing Cleanrooms for NASA OSIRIS-REx and Hayabusa2 Curation Facility

astromaterials curation↗

DOE OSTI2026

Ten questions concerning Large Language Models (LLMs) for building applications

Large Language Models (LLMs) are emerging as powerful AI tools capable of transforming how building information is collected, processed, analyzed, and applied across diverse research areas. Their capabilities can help building operators, facility managers and other stakeholders such as designers, architects and engineers by providing actionable insights for decision-making across planning, construction, operations, and maintenance of buildings and facilities. This paper explores ten key questions concerning the role of LLMs in shaping sustainable, intelligent, and human-centric buildings. From fundamental definitions to advanced applications, we examine how LLMs facilitate decision-making across the life cycle of buildings and energy systems. LLMs can enhance life cycle assessments (LCA), building energy simulations, and real-time data integration, empowering more efficient and adaptive human-AI environments. They can also contribute to streamlining regulatory compliance, improving post-occupancy evaluations, and fostering more inclusive and participatory design processes. Additionally, this paper addresses the ethical challenges posed by LLMs, such as bias, data privacy, and environmental impacts, and explores their potentials in advancing intelligent digital twins (DT) for ongoing building operations and maintenance. Built upon our applied research using LLMs and the review of tools, datasets, and research gaps, we provide a forward-looking perspective on how LLMs can drive innovation, collaboration, and productivity in the built environment while supporting ethical and effective implementation.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2025

Conceptual Design of a Water Tank Critical Facility for SPARC

Critical experiments, sometimes referred to zero-power reactors, are crucial tools in developing and validating nuclear physics predictions and thus an indispensable capability to ensure criticality safety during all parts of the nuclear fuel cycle and in reducing uncertainties in reactor physics predictions toward optimizing nuclear energy production. The System Physics Advanced Reactor Facility (SPARC) project was recently initiated to enable large-scale criticality experiments using a horizontal split table machine well suited toward solid core materials systems (fuel, moderator, reflector). The facility selected for this mission was a former pool-type research reactor building and thus also well suited toward a second critical experiment capability able to house full-size light-water reactor (LWR) fuel bundles. A conceptual design study was undertaken to review past water tank critical experiments used for LWR physics experiments and to develop an early engineering design for a new critical assembly tank (CAT). The work described here shows that a relatively simple CAT concept can be constructed and deployed in the SPARC facility to meet the urgent demands for new critical experiments on advanced LWR fuel bundles designs. The SPARC facility layout is conducive to the receipt and upending of LWR fuel bundles using existing containers and equipment from the LWR industry. The facility’s overhead crane can then be used to handle fuel bundles and place them in a vertical storage rack or in the CAT for critical experiments, both of which fit within the building’s “open basement” alongside other equipment planned for SPARC and the horizontal split table. A slightly lower area in the basement can serve as a large drain tank so that fail-safe valves drain the CAT reactor tank for safe shutdown. Neutronic configurations were determined where a 3 × 3 array of fuel bundles can be surrounded by full-length “loose rods” to adjust reactivity so that critical is achieved when the bundles are fully submerged. Viable configurations were determined for both pressurized- and boiling-water-reactor-type fuel bundles. This design concept was used to develop an early planning basis for establishing the CAT capability alongside the otherwise planned SPARC project in order to help streamline the process. Recent presidential executive orders have highlighted the need to achieve power uprates in LWR plants and the CAT capability will be a crucial element of these initiatives. Based on the work described herein, it is recommended that an earnest and timely project begin in order to establish this urgently needed capability.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2025

Future grid mix impacts on whole-building life cycle assessment

Building construction and operation are a significant contribution to global greenhouse gas emissions, so understanding and mitigating emissions is crucial for reliable and realistic emissions accounting. Whole-building Life Cycle Assessment (WBLCA) is an emissions accounting method that considers lifetime environmental impacts of a building during its construction, operation, and eventual end-of-life. When performing WBLCAs, emission calculations from the building's operation over the entire building lifespan are typically based on today's energy grid mixes. This method does not consider changes or advancements in the clean energy proportion within the grid mix and can over or under-inflate results, skewing the ratio of embodied vs. operational environmental impacts. While a variety of prediction tools estimate what future grid emissions might be, predictions can vary widely. To predict the clean energy ratio within future grid mixes and the potential impact these changes might have on WBLCA, annual data from several existing U.S. grid models was averaged and probabilistic modeling was used to extend the usable projections of shorter forecasts. Results show that clean energy sources will likely continue to increase over time, although the rate of growth varies by model. On average, by 2085, the clean energy penetration of the grid is projected to reach ~81% and renewable energy is projected to reach ~71%, although no widespread consensus is reached. To understand how the future grid mix impacts lifetime building emissions within a WBLCA context, the team analyzed two 2021 IECC-compliant all-electric residential buildings: one built from traditional materials and construction processes and the other built with carbon sequestering materials and modular assembly, with a portion of energy generated on site. The results indicate that a moderate estimate of future electricity grid mixes shows a reduction of yearly operational emissions for traditional residential buildings of 55% between 2025 and 2085, and a corresponding reduction of 48% of total emissions over a 60 year building lifespan. This study offers a nuanced approach to account for the variability of future grid mix models and provides an average trend-line based on a robust collection of scenarios.

Life Cycle Assessment (LCA)↗

NASA NTRS1974

Technology Utilization House Study Report

The objectives of Project TECH are: (1) to construct a single family detached dwelling for demonstrating the application of advanced technology and minimizing the requirement for energy and utility services, and (2) to help influence future development in home construction by defining the interaction of integrated energy and water management systems with building configuration and construction materials. Components and methods expected to be cost effective over a 20 year span were studied. Emphasis was placed on the utilization of natural heating and cooling characteristics. Orientation and location of windows, landscaping, natural ventilation, and characteristics of the local climate and microclimate were intended to be used to best advantage. Energy conserving homes are most efficient when design for specific sites, therefore project TECH should not be considered a prototype design suitable for all locations. However, it does provide ideas and analytical methods which can be applied to some degree in all housing.

Source record↗

NASA NTRS2005

Advanced Joining Technology: Simple, Strong, and Secure

The space-age materials that NASA employs in its spacecraft and satellites have different attributes than the building materials that can work for Earthly uses. These materials do not behave like the typical construction materials, and therefore, require new methods for construction. Work done at NASA s Langley Research Center in the realm of active solder joining has led to a new, self-bonding solder that enables high conductivity, as well as the metallic joining of carbon and ceramic materials to a wide range of metals. The original work involved evaluating high- and low-temperature joining technologies for joining carbon composite structures for use in thermal management and reusable launch vehicles. The initial plan for this innovation was to lower the weight of battery packs in satellites. It was a success. NASA scientists found use for this technology in fabricating a thermal management package for battery compartments in the Earth Observing System (EOS) satellites, but it is also being used by the Agency for space radiator panels. Because it is light, simple to use, and economical, NASA will likely find other uses for this solder, just as outside of the Space Agency, this unique bond is finding many practical applications.

Source record↗

DOE OSTI2025

Decarbonizing residential buildings in the United States: A comparative analysis of households and construction professionals

In this study, we present a comparative analysis of surveys distributed to home occupants and construction professionals in the U.S., focused on energy upgrades and electrification retrofits that support residential building decarbonization. The surveys were executed by separate research groups and combined for this study. The study examines the decision-making, sentiments, perceptions, experiences, and practices of both groups by analyzing data from three separate surveys. These surveys assess technologies, attitudes, awareness, motivations, barriers, and opportunities related to energy retrofits and electrification. The analysis highlights key differences in the perceptions and behaviors of households and construction professionals, revealing substantial barriers to achieving decarbonization goals. For example, households cite climate change and sustainability as key motivators for pursuing energy retrofits (89%), while construction industry professionals view these themes as less important for their clients (44%). This suggests an opportunity for the construction industry to align its messaging with the values that households prioritize, helping to advance residential decarbonization. Overall, the study identifies challenges faced by both groups, factors influencing the adoption of energy-efficient practices, and inconsistencies between occupant and construction industry professionals' views. These insights contribute to the development of targeted strategies and policies to accelerate the decarbonization of residential buildings in the U.S.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

NASA NTRSDate not supplied

Mars Sample Receiving Facility Research and Development to Enable Preservation, Safe Containment, and Scientific Research of Martian Samples on Earth

NASA and ESA are working together to plan a joint campaign to potentially bring back the first Martian samples to Earth in the early 2030s. On the surface of Mars, the Mars 2020Perseverance Rover is selecting and packaging samples that could be returned to Earth for careful examination by an international team of scientists. In preparation for this historic sample return, advance planning is underway to design and build a Mars Sample Receiving Facility (SRF) in the mid-2020s. In 2022, a Mars Sample Receiving Facility Assessment Study(MSAS) will be conducted to further define construction modality and capability options for a facility in the conterminous United States. Since Mars Sample Return (MSR) is currently categorized as a planetary protection restricted Earth return, this new facility would feature biosafety level 4 (BSL-4)-like high containment to protect Earth’s biosphere from any potential hazard. In addition, the facility also requires integration of cleanroom technologies to mitigate against terrestrial contamination and preserve sample integrity for science investigations. The integration of both clean handling and high containment requires significant technology research and development (R&D) by the mid-2020s to support the definition and planning of a SRF before commencing the site specific design phase. The SRF project will need to solidify the inorganic, organic, and biological contamination control (CC) requirements for the facility. This could entail a translation of Mars 2020 mission CC requirements for geologic material to engineering requirements for surfaces and airborne molecular contamination inside isolators and cleanrooms. In tandem, the project will need to determine precision cleaning and sterilization approaches for cleanrooms, isolators, equipment, and tools. Initial material selections for the facility construction materials, cleanrooms, isolators, and BSL-4 suits/garments are an important activity. The recent construction of the OSIRIS-REx and Hayabusa2 curation cleanroom laboratories greatly benefited from early materials testing, before the design phase, to reduced organic outgassing and particulate shedding inside the laboratory. While the early biohazard investigations in the SRF may deem the samples safe to release to laboratories throughout the world, sterilization methods need to be defined to safely release Martian samples. One key aspect of enabling simultaneous sample containment and cleanliness is the concept of a Double-Walled Isolator (DWI) that ESA has been pursuing. Further R&D is needed about DWIs, sample handling, and instrumentation interfaces before beginning the SRF site specific design phase. A working isolator/DWI engineering model should be developed and fabricated. Isolator sizes, connections, pass-through antechambers, and configurations and basic interfaces with instruments and tools as well as the use of robotic, mechanical, and/or human manipulation need to be considered. Inert high purity gas supply (one-pass or recirculation) and other isolator utilities must be determined. Special accommodations for large instruments (e.g., XCT,SEM, etc.) need to be developed. Techniques for opening the sample tubes packaged by M2020and extracting the headspace gas while keeping samples pristine will be challenging, requiring additional R&D, and engagement of the M2020 project. In addition, careful micromanipulation for subdivision and packaging of samples will also need to be included. These combined R&D activities are important before commencing the SRF design phase to ensure safe biohazard containment, sample preservation, and science integrity for the samples that would be studied in the SRF and in laboratories around the world.

mars sample return↗

DOE OSTI2024

MICROREACTOR APPLICATIONS, RESEARCH, VALIDATION, AND EVALUATION (MARVEL) REACTOR ? STATUS, CONSTRUCTION, AND TESTING

The paper presents the current status of the Microreactor Applications, Research, Validation, and Evaluation (MARVEL) microreactor design, qualification testing, fabrication, and high-level construction schedule. An overview of initial criticality, low power physics testing, and start-up testing is included, as well as an overview of the envisioned processes in which end-users can engage the project for access to operational data or specific demonstrations. Designed by the Idaho National Laboratory (INL) under the auspices of the US Department of Energy’s Microreactor Program for construction and operation at the INL, MARVEL is a small, fully functional advanced reactor with UZrH fuel and thermal output of 85 kW. It offers a unique opportunity for scaled demonstrations that can dramatically accelerate the design, licensing, and deployment of commercial microreactors for power production or process heat applications. MARVEL’s objective is to build a small liquid-metal thermal reactor at the INL to demonstrate design and operating processes for microreactors, microgrid integration, and process heat applications. MARVEL finished 90%-final-design in September 2023 and completed an independent project assessment in early 2024. Fabrication of long-lead components and fuel, safety analysis review, and procurement for construction are underway. MARVEL assembly and construction will start in 2025 and fuel loading is expected in mid- 2027. Initial criticality will be performed in a dry condition in late 2027, followed by loading of NaK coolant and start-up testing. Approximately six months later, release for unrestricted operations will enable subsequent testing of microreactor characteristics, microgrid integration and select heat extraction applications.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

NASA NTRS2008

Advanced Diagnostic and Prognostic Testbed (ADAPT) Testability Analysis Report

As system designs become more complex, determining the best locations to add sensors and test points for the purpose of testing and monitoring these designs becomes more difficult. Not only must the designer take into consideration all real and potential faults of the system, he or she must also find efficient ways of detecting and isolating those faults. Because sensors and cabling take up valuable space and weight on a system, and given constraints on bandwidth and power, it is even more difficult to add sensors into these complex designs after the design has been completed. As a result, a number of software tools have been developed to assist the system designer in proper placement of these sensors during the system design phase of a project. One of the key functions provided by many of these software programs is a testability analysis of the system essentially an evaluation of how observable the system behavior is using available tests. During the design phase, testability metrics can help guide the designer in improving the inherent testability of the design. This may include adding, removing, or modifying tests; breaking up feedback loops, or changing the system to reduce fault propagation. Given a set of test requirements, the analysis can also help to verify that the system will meet those requirements. Of course, a testability analysis requires that a software model of the physical system is available. For the analysis to be most effective in guiding system design, this model should ideally be constructed in parallel with these efforts. The purpose of this paper is to present the final testability results of the Advanced Diagnostic and Prognostic Testbed (ADAPT) after the system model was completed. The tool chosen to build the model and to perform the testability analysis with is the Testability Engineering and Maintenance System Designer (TEAMS-Designer). The TEAMS toolset is intended to be a solution to span all phases of the system, from design and development through health management and maintenance. TEAMS-Designer is the model-building and testability analysis software in that suite.

Ossenfort, John↗

NASA NTRS1978

Tech House

The members of the Swain family- Dr. Charles "Bill" Swain, wife Elaine, daughter Carol, 17, son "Chuck", 12, and dog Susie have an interesting assignment. They are active participants in an important NASA research program involving the application of space-age technology to home construction. b' Transplanted Floridians, the Swains now reside in NASA's Tech House, lo~atedat Langley Research Center, Hampton, Virginia. Their job is to use and help evaluate the variety of advanced technology systems in Tech House. A contemporary three-bedroom home, Tech House incorporates NASA technology, the latest commercial building techniques and other innovations, all designed to reduce energy and water consumption and to provide new levels of comfort, convenience, security and fire safety. Tech House equipment performed well in initial tests, but a house is not a home until it has people. That's where the Swains come in. NASA wants to see how the various systems work under actual living conditions, to confirm the effectiveness of the innovations or to determine necessary modifications for improvement. The Swains are occupying the house for a year, during which NASA engineers are computer monitoring the equipment and assembling a record of day-to-day performance. . Tech House is a laboratory rather than a mass production prototype, but its many benefits may influence home design and construction. In a period of sharply rising utility costs, widespread adoption of Tech House features could provide large-scale savings to homeowners and potentially enormous national benefit in resources conservation. Most innovations are aerospace spinoffs: Some of the equipment is now commercially available; other systems are expected to be in production within a few years. Around 1980, a Tech House-type of home could be built for $45-50,000 (1 976 dollars). It is estimated that the homeowner would save well over $20,000 (again 1976 dollars) in utility costs over the average mortgage span of 20 years.

Source record↗

DOE OSTI2025

Comparative life cycle assessment of a modular cross-laminated timber residential building designed for disassembly and reuse versus traditional wood frame construction

There is a need for affordable housing across the U.S., with high-performance modular and prefabricated buildings providing a logical avenue for meeting some of this demand. However, there is a need to balance high performance construction – including low emissions – with affordability. To provide a proof-of-concept in meeting these goals, the Circular Home is a cross-laminated timber (CLT)-based deconstructible and reconfigurable single-family residence that meets high performance targets in moisture, energy, design, economics, and life cycle assessment (LCA). This study focuses on the LCA, presenting a cradle-to-cradle whole-building life cycle assessment (WBLCA) for the Circular Home and a functionally equivalent Baseline Home constructed with traditional materials and methods. The functional unit is 1 m 2 of gross floor area across 60 years. Revit building information models (BIM) provided material quantities and Tally LCA was utilized for impact data (inclusive of biogenic carbon sequestration), supplemented with manufacturer environmental product declarations (EPDs). The Circular Home outperforms the baseline residence in most measured impact categories, including global warming potential (GWP), producing −2.73 kgCO 2 eq/m 2 in embodied emissions, whereas the modeled baseline has an embodied GWP of 428 kgCO 2 eq/m 2 . The careful material selection and advanced building design optimizes performance, with the Circular Home containing only −0.006 times the embodied emissions and −0.02 times the operational emissions of its traditional counterpart. Finally, the unique contribution of this work is in the environmental impact comparison of a high-performance modular CLT structure that can be affordably scaled and mass produced in a U.S. market, compared to typical single family home construction.

Circularity↗

NASA NTRS2019

Design and Analysis of a Tool for Automated Fiber Placement of Composite Wind Tunnel Blades

For decades, composite wind tunnel blades have been constructed using labor-intensive hand layup processes. Automated Fiber Placement (AFP) is a relatively new technology that has not seen widespread use in manufacturing composite wind tunnel blades. AFP offers the potential for reduced manufacturing time, reduced cost, and improved consistency compared to traditional hand layup procedures. These manufacturing qualities are becoming increasingly important as existing wind tunnel blades are replaced due to impact damage or wear and tear from decades of use. Researchers at the NASA Langley Research Center are currently using the Integrated Structural Assembly of Advanced Composites (ISAAC) facility to investigate the feasibility of AFP for manufacturing composite wind tunnel blades. ISAAC uses manufacturing tools as surfaces on which to place fiber tows. A manufacturing tool was developed for using AFP to build a wind tunnel blade shape. This paper presents the structural design and analysis of this tool, for use with AFP, constructed from high temperature thermoplastics. The tool fabricated by this design process was successfully used for AFP and oven cure of two representative airfoil shaped composite structures.

Brian Mason↗

NASA NTRS1999

Long-Time Numerical Integration of the Three-Dimensional Wave Equation in the Vicinity of a Moving Source

We propose a family of algorithms for solving numerically a Cauchy problem for the three-dimensional wave equation. The sources that drive the equation (i.e., the right-hand side) are compactly supported in space for any given time; they, however, may actually move in space with a subsonic speed. The solution is calculated inside a finite domain (e.g., sphere) that also moves with a subsonic speed and always contains the support of the right-hand side. The algorithms employ a standard consistent and stable explicit finite-difference scheme for the wave equation. They allow one to calculate tile solution for arbitrarily long time intervals without error accumulation and with the fixed non-growing amount of tile CPU time and memory required for advancing one time step. The algorithms are inherently three-dimensional; they rely on the presence of lacunae in the solutions of the wave equation in oddly dimensional spaces. The methodology presented in the paper is, in fact, a building block for constructing the nonlocal highly accurate unsteady artificial boundary conditions to be used for the numerical simulation of waves propagating with finite speed over unbounded domains.

Ryabenkii, V. S.↗