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Results for “Digital Fabrication”

Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 73 records · Page 4
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

The 3D printing and modeling of functionally graded Kelvin foams for controlling crushing performance

Mechanical impact protection is an important consideration in many applications, ranging from product transportation to sports. Cellular materials are typically used due to their desirable energy absorption properties and light weight. However, their large deformation and rate dependent responses (especially of polymer foams) are challenging to consider in design. Additionally, the use of foams with uniform properties, such as uniform density and uniform stiffness, often restricts the designed foams to only be suitable for a narrow range of mechanical impact conditions whereas real applications commonly face unpredictable situations. 3D printing offers fabrication flexibility and thus opens the door to create foams with tailored properties. In this work, we investigate the feasibility of using 3D printing for functionally graded foams (FGFs) that are optimal over a broad range of mechanical environments. The foams are fabricated by the recently developed grayscale digital light processing (g-DLP) method which can print parts with locally designed properties. These foams are tested under drop test conditions and with slower displacement control. We also model the large deformation behavior of FGFs using finite element analysis in which we account for the different viscoelastic behaviors of the distinct grayscale regions. We then use the model to examine the impact mitigation capabilities of FGFs in different loading scenarios. Finally, we show how FGFs can be used to satisfy real-world design goals using the case study of a motorcycle helmet. In contrast to prior work, we investigate continuous, functionally graded foams of a single density that differ in their viscoelastic responses. This work provides further insight into the benefits of viscoelastic properties and modulus graded foams and presents a manufacturing approach that can be used to produce the next generation of flexible lattice foams as mechanical absorbers.

3D printing↗
NASA NTRS1972

A very high speed hard decision sequential decoder.

Description of a 40-Mbps hard-decision sequential decoder for high-data-rate coding systems for earth-orbiting space missions with power-limited links. A prototype decoder has been designed and fabricated using the fastest commercially available digital integrated circuits, MECL III. Thus far, an internal computational rate of 70 million computations per second has been achieved. Computational efficiency of the decoding algorithm was greatly improved by incorporating two modifications to the Fano algorithm - 'double quick threshold loosening' and 'diagonal steps.' Preliminary results indicate that an output error rate of 0.00001 can be achieved with E sub b/N sub zero less than 5.4 dB at data rates up to 40 Mbps. At lower data rates, even less signal energy is required. This decoder is believed to be at least five times faster than any previous sequential decoder.

Gilhousen, K. S.↗
NASA NTRS1975

A study to analyze six band multispectral images and fabricate a Fourier transform detector

An automatic Fourier transform diffraction pattern sampling system, used to investigate techniques for forestry classification of six band multispectral aerial photography is presented. Photographs and diagrams of the design, development and fabrication of a hybrid optical-digital Fourier transform detector are shown. The detector was designed around a concentric ring fiber optic array. This array was formed from many optical fibers which were sorted into concentric rings about a single fiber. All the fibers in each ring were collected into a bundle and terminated into a single photodetector. An optical/digital interface unit consisting of a high level multiplexer, and an analog-to-digital amplifier was also constructed and is described.

Shackelford, R. G.↗
NASA NTRS1995

Laser Doppler Velocimetry and full-field soot volume fraction

Since its introduction in the mid-sixties, Laser Doppler Velocimetry (LDV) has become one of the most widely used methods for the measurement of flows. Its remote and essentially non-intrusive nature provides an invaluable tool for a variety of difficult measurement situations which would be otherwise inaccessible. The high spatial resolution and rapid temporal response afforded by this technique are well suited to the determination of spatial and temporal details of flow fields, as well as characterization of turbulence. Advances in the understanding of the properties of LDV signals, accompanied by technological advances in coherent laser sources, detectors of high sensitivity and low noise, optical fabrication techniques and high-speed digital signal processing architectures have resulted in systems of increased accuracy and flexibility. As will be shown, recent progress in solid-state lasers and photo-detectors has been beneficial insofar as the compatibility of this method with the unique and severe constraints inherent in microgravity combustion science experiments.

Greenberg, Paul S.↗
NASA NTRS2012

The Multiple Use Plug Hybrid for NanoSats (MUPHyN) Miniature Thruster

The Multiple Use Plug Hybrid (for) Nanosats is a prototype thruster is being developed to fill a niche application for NanoSat-scale spacecraft propulsion. When fully developed, the MUPHyN thruster will provide an effective and low-risk propulsive capability that could enable multiple NanoSats to be independently re-positioned after deployment from a parent launch vehicle. Because the environmentally benign, chemically-stable propellants are mixed only within the combustion chamber after ignition and the flow rate of the fuel is determined by a pyrolysis mechanism that is nearly independent of pressure or fuel grain defects, the system is inherently safe and can be piggy-backed near a secondary payload with little or no overall mission risk increase to the primary payload. The MUPHyN thruster uses safe-handling and inexpensive nitrous oxide (N2O) and acrylonitrile-butadiene-styrene (ABS) as propellants. Fused Deposition Modeling (FDM), a direct digital manufacturing process, is used to fabricate short-form-factor solid fuel grains with multiple helical combustion ports from ABS thermoplastic. This manufacturing process allows for the rapid development and manufacture of complex fuel grain geometries that are not possible to extrude or cast using conventional methods. This technology enables the construction of fuel grains with length-to-diameter ratios appropriate for incorporation into CubeSats while maintaining high surface areas and regression rates that allow the system to maintain a near optimal oxidizer to fuel ratio. The MUPHyN system provides attitude control torques by using secondary-injection thrust vectoring on a truncated aerospike nozzle. This configuration allows large impulse delta V burns and small impulse attitude control firings to be performed with the same system. To ensure survivability during extend duration burns, the MUPHyN incorporates a novel regenerative cooling design where the N2O oxidizer flows through a cooling path embedded in the aerospike nozzle before being injected into the combustion chamber near the nozzle base.

Eilers, Shannon D.↗
DOE OSTI2026

Physicochemical properties of digital light processing 3D-Printed alumina and mullite ceramics

Alumina ceramics fabricated using conventional techniques such as uniaxial pressing or injection molding are popular due to their low density, excellent insulation, and mechanical properties. However, these methods often limit the fabrication of complex geometries with high dimensional accuracy due to tooling constraints and limited design freedom. To overcome these limitations, this study employed Digital Light Processing (DLP) additive manufacturing (AM), which enables the production of precise structures. In addition, the optimization of sintering parameters to enhance the densification and performance of alumina and mullite ceramics was investigated, with a specific focus on how varying sintering temperatures and hold times affect part shrinkage, geometric accuracy, and material integrity. Flexural strength of both alumina and mullite specimens was clearly influenced by the way the layers was stacked. When layers were arranged across the direction of the applied load (Z = 4; XZ), the strength was higher than when they were stacked along the same direction as the load (Z = 3; XY). Weibull analysis based on these results showed high modulus values across all samples, indicating good reliability in the flexural strength measurements. This reliability, combined with the clear influence of sintering parameters, highlights how processing conditions effect the material properties and mechanical performance of parts produced through DLP additive manufacturing. In conclusion, these findings open new avenues for ceramic AM across various applications, enhancing the potential for innovation in fields such as aerospace, biomedical engineering, and energy.

36 MATERIALS SCIENCE↗
NASA NTRS1977

DIGIMEN, optical mass memory investigations, volume 2

The DIGIMEM phase of the Optical Mass Memory Investigation Program addressed problems related to the analysis, design, and implementation of a direct digital optical recorder/reproducer. Effort was placed on developing an operational archival mass storage system to support one or more key NASA missions. The primary activity of the DIGIMEM program phase was the design, fabrication, and test and evaluation of a breadboard digital optical recorder/reproducer. Starting with technology and subsystem perfected during the HOLOMEM program phase, a fully operational optical spot recording breadboard that met or exceeded all program goals was evaluated. A thorough evaluation of several high resolution electrophotographic recording films was performed and a preliminary data base management/end user requirements survey was completed.

Source record↗
DOE OSTI2022

A sub-picosecond digitally-controlled phase delay

The use of precision timing measurements will be a major tool at the HL-LHC, where it will be used to suppress pile-up and to search for long-lived particles. To control a reference clock with sub-picosecond accuracy, we have fabricated in the TSMC 65 nm process a digitally controlled phase shifter. It is composed of a chain of 66 cells, each with a digitally controlled planar wave guide with either a short or long delay. With this a reference clock’s phase can be controlled to a precision of 200 fs with dynamic range of 12 ps.

Instruments & Instrumentation↗
DOE OSTI2024

Experimental Examination of Additively Manufactured Patterns on Structural Nuclear Materials for Digital Image Correlation Strain Measurements

Abstract Background There are a limited number of commercially available sensors for monitoring the deformation of materials in-situ during harsh environment applications, such as those found in the nuclear and aerospace industries. Such sensing devices, including weldable strain gauges, extensometers, and linear variable differential transformers, can be destructive to material surfaces being investigated and typically require relatively large surface areas to attach (> 10 mm in length). Digital image correlation (DIC) is a viable, non-contact alternative to in-situ strain deformation. However, it often requires implementing artificial patterns using splattering techniques, which are difficult to reproduce. Objective Additive manufacturing capabilities offer consistent patterns using programmable fabrication methods. Methods In this work, a variety of small-scale periodic patterns with different geometries were printed directly on structural nuclear materials (i.e., stainless steel and aluminum tensile specimens) using an aerosol jet printer (AJP). Unlike other additive manufacturing techniques, AJP offers the advantage of materials selection. DIC was used to track and correlate strain to alternative measurement methods during cyclic loading, and tensile tests (up to 1100 µɛ) at room temperature. Results The results confirmed AJP has better control of pattern parameters for small fields of view and facilitate the ability of DIC algorithms to adequately process patterns with periodicity. More specifically, the printed 100 μm spaced dot and 150 μm spaced line patterns provided accurate measurements with a maximum error of less than 2% and 4% on aluminum samples when compared to an extensometer and commercially available strain gauges. Conclusion Our results highlight a new pattern fabrication technique that is form factor friendly for digital image correlation in nuclear applications.

Novich, K. A. (ORCID:0000000204466022)↗
NASA NTRS2003

Low-Power Radio-Frequency SiGe Analog-to-Digital Converter

A low-power, radio-frequency analog-to-digital converter (RF-ADC) for soil moisture remote sensing was designed and fabricated. The RF-ADC is the fundamental component used in a direct-sampling digital radiometer, which is proposed to minimize the power dissipation and system complexity for synthetic thinned array radiometer. The circuit was implemented using 0.8 micron 35-GHz silicon germanium BiCMOS technology. The total power dissipation was 222 mW.

Thompson, Willie L, II↗
DOE OSTI2024

3D Printing of Functional Hydrogel Devices for Screenings of Membrane Permeability and Selectivity

Developing a fundamental understanding of the effects of varying ligand chemistries on mass transport rates is key to designing membranes with solute-specific selectivity. While permeation cells offer a robust method to characterize membrane performance, they are limited to assessing a single membrane chemistry or salt solution per test. As a result, investigating the effects of varying ligand chemistries on membrane performance can be a tedious process, involving both the preparation of multiple samples and numerous, time-consuming permeation tests. This study uses digital light processing (DLP) 3D printing to fabricate a millifluidic flow-based permeation device made from a hydrogel active ester network that can be easily functionalized with ion-selective ligands. Without the need for bonding or assembly steps, ligands can be introduced and tested in the permeation device by simply injecting a small volume of a ligand solution. Various salt concentrations and molecular species can be cycled through a single device by switching the solution feeding into the salt reservoir, thereby reducing the number of samples needed for permeability and selectivity screenings. This research sets the groundwork for formulation development and postprocessing methods to 3D-print functional millifluidic devices capable of assessing solute selectivity in membranes and polymer adsorbents for aqueous separations. In this work, comparable salt permeability trends were observed with both 3D-printed devices and traditional assays. Devices were functionalized with an imidazole ligand to investigate salt permeability and selectivity of monovalent and divalent salts. Measurements showed increasing permeability for monovalent salts (NaCl) relative to divalent salts (MgCl 2 , CuCl 2 ) in functionalized membranes, with higher monovalent/divalent selectivity at increasing imidazole grafting densities. Here, the methods and findings described here represent a step toward developing higher-throughput methods with 3D-printed devices for screening the effects of ligand chemistry on mass transport rates in membrane materials.

36 MATERIALS SCIENCE↗
NASA NTRS1978

JPL 2-to-the-20th-power channel 300 MHz bandwidth digital spectrum analyzer

A million (two to the 20th power) channel, 300 MHz bandwidth, digital spectrum analyzer was considered. The design, fabrication, and maintenance philosophy of the modular, pipelined, fast fourier transform (FFT) hardware are described. The spectrum analyzer will be used to examine the region from 1.4 GHz to 26 GHz for radio frequency interference which may be harmful to present and future tracking missions of the Deep Space Network. The design has application to the search for extraterrestrial intelligence signals and radio science phenomena.

Morris, G. A., Jr.↗
NASA NTRS1983

High-temperature optically activated GaAs power switching for aircraft digital electronic control

Gallium arsenide high-temperature devices were fabricated and assembled into an optically activated pulse-width-modulated power control for a torque motor typical of the kinds used in jet engine actuators. A bipolar heterojunction phototransistor with gallium aluminum arsenide emitter/window, a gallium arsenide junction field-effect power transistor and a gallium arsenide transient protection diode were designed and fabricated. A high-temperature fiber optic/phototransistor coupling scheme was implemented. The devices assembled into the demonstrator were successfully tested at 250 C, proving the feasibility of actuator-located switching of control power using optical signals transmitted by fibers. Assessments of the efficiency and technical merits were made for extension of this high-temperature technology to local conversion of optical power to electrical power and its control at levels useful for driving actuators. Optical power sources included in the comparisons were an infrared light-emitting diode, an injection laser diode, tungsten-halogen lamps and arc lamps. Optical-to-electrical power conversion was limited to photovoltaics located at the actuator. Impedance matching of the photovoltaic array to the load was considered over the full temperature range, -55 C to 260 C. Loss of photovoltaic efficiency at higher temperatures was taken into account. Serious losses in efficiency are: (1) in the optical source and the cooling which they may require in the assumed 125 C ambient, (2) in the decreased conversion efficiency of the gallium arsenide photovoltaic at 260 C, and (3) in impedance matching. Practical systems require improvements in these areas.

Berak, J. M.↗
NASA NTRS1987

Precision pointing and control of flexible spacecraft

The problem and long term objectives for the precision pointing and control of flexible spacecraft are given. The four basic objectives are stated in terms of two principle tasks. Under Task 1, robust low order controllers, improved structural modeling methods for control applications and identification methods for structural dynamics are being developed. Under Task 2, a lab test experiment for verification of control laws and system identification algorithms is being developed. For Task 1, work has focused on robust low order controller design and some initial considerations for structural modeling in control applications. For Task 2, work has focused on experiment design and fabrication, along with sensor selection and initial digital controller implementation. Conclusions are given.

Bantell, M. H., Jr.↗
NASA NTRS1991

SPROC: A multiple-processor DSP IC

A large, single-chip, multiple-processor, digital signal processing (DSP) integrated circuit (IC) fabricated in HP-Cmos34 is presented. The innovative architecture is best suited for analog and real-time systems characterized by both parallel signal data flows and concurrent logic processing. The IC is supported by a powerful development system that transforms graphical signal flow graphs into production-ready systems in minutes. Automatic compiler partitioning of tasks among four on-chip processors gives the IC the signal processing power of several conventional DSP chips.

Davis, R.↗
NASA NTRS1988

Ku-band high efficiency GaAs MMIC power amplifiers

The development of Ku-band high efficiency GaAs MMIC power amplifiers is examined. Three amplifier modules operating over the 13 to 15 GHz frequency range are to be developed. The first MMIC is a 1 W variable power amplifier (VPA) with 35 percent efficiency. On-chip digital gain control is to be provided. The second MMIC is a medium power amplifier (MPA) with an output power goal of 1 W and 40 percent power-added efficiency. The third MMIC is a high power amplifier (HPA) with 4 W output power goal and 40 percent power-added efficiency. An output power of 0.36 W/mm with 49 percent efficiency was obtained on an ion implanted single gate MESFET at 15 GHz. On a dual gate MESFET, an output power of 0.42 W/mm with 27 percent efficiency was obtained. A mask set was designed that includes single stage, two stage, and three stage single gate amplifiers. A single stage 600 micron amplifier produced 0.4 W/mm output power with 40 percent efficiency at 14 GHz. A four stage dual gate amplifier generated 500 mW of output power with 20 dB gain at 17 GHz. A four-bit digital-to-analog converter was designed and fabricated which has an output swing of -3 V to +/- 1 V.

Tserng, H. Q.↗