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Materials Selection and Their Characteristics as Used in Rapid Prototyping

NASA's Marshall Space Flight Center (MSFC) conducted a program to evaluate six technologies used in Rapid Prototyping (RP) to produce investment casting patterns. In this paper, RP refers to the collective additive fabrication technologies known as Solid Free-Form Fabrication. Such technologies are being used with increasing frequency in manufacturing applications, due in part to their rapidly expanding capabilities to fabricate models from many types of materials. This study used ABS plastic, polycarbonate, TrueForm PM6, epoxy resin, paper, starch, and wax. The baseline model was a semi-complex prototype fuel pump housing, intended for use in the X-33 reusable launch vehicle. All models were shelled in a production- grade colloidal silica ceramic. Primary coats were zircon-base flour with zircon backup, while secondary coats were silica grains with a tabular alumina backup. Each model was shelled in an identical manner, using the same atmospheric conditions and drying times, as well as the same number of layers. Bake-outs and firing cycles were consistent with the leach ability of each material. Preheat and bath temperatures were also kept consistent. All molds were cast in vacuum using a hydrogen-resistant superalloy (NASA- 23) that was developed in-house. The final technical evaluation included detailed measurements of the model and the final casting, in order to determine any dimensional changes caused by different pattern materials, as well as documentation of all defects and any obvious refractory/model reactions. Prototype production costs were estimated for each method and taken into consideration during trade-off analysis.

Cooper, K.

PRMS Data Warehousing Prototype

Project and Resource Management System (PRMS) is a web-based, mid-level management tool developed at KSC to provide a unified enterprise framework for Project and Mission management. The addition of a data warehouse as a strategic component to the PRMS is investigated through the analysis design and implementation processes of a data warehouse prototype. As a proof of concept, a demonstration of the prototype with its OLAP's technology for multidimensional data analysis is made. The results of the data analysis and the design constraints are discussed. The prototype can be used to motivate interest and support for an operational data warehouse.

Guruvadoo, Eranna K.

Research Prototype: Automated Analysis of Scientific and Engineering Semantics

Physical and mathematical formulae and concepts are fundamental elements of scientific and engineering software. These classical equations and methods are time tested, universally accepted, and relatively unambiguous. The existence of this classical ontology suggests an ideal problem for automated comprehension. This problem is further motivated by the pervasive use of scientific code and high code development costs. To investigate code comprehension in this classical knowledge domain, a research prototype has been developed. The prototype incorporates scientific domain knowledge to recognize code properties (including units, physical, and mathematical quantity). Also, the procedure implements programming language semantics to propagate these properties through the code. This prototype's ability to elucidate code and detect errors will be demonstrated with state of the art scientific codes.

Stewart, Mark E. M.

PRMS Data Warehousing Prototype

Project and Resource Management System (PRMS) is a web-based, mid-level management tool developed at KSC to provide a unified enterprise framework for Project and Mission management. The addition of a data warehouse as a strategic component to the PRMS is investigated through the analysis, design and implementation processes of a data warehouse prototype. As a proof of concept, a demonstration of the prototype with its OLAP's technology for multidimensional data analysis is made. The results of the data analysis and the design constraints are discussed. The prototype can be used to motivate interest and support for an operational data warehouse.

Guruvadoo, Eranna K.

Efficient Plasma Production in Low Background Neutral Pressures with the M2P2 Prototype

Mini-Magnetospheric Plasma Propulsion (M2P2) seeks the creation of a large-scale (10 km radius) magnetic wall or bubble (i.e. a magnetosphere) by the electromagnetic inflation of a small-scale (20 cm radius) dipole magnet. The inflated magnetosphere will intercept the solar wind and thereby provide high-speed propulsion with modest power and fuel requirements due to the gain provided by the ambient medium. Magnetic field inflation is produced by the injection of plasma onto the dipole magnetic field eliminating the need for large mechanical structures and added material weight at launch. For successful inflation of the magnetic bubble a beta near unity must be achieved along the imposed dipole field. This is dependent on the plasma parameters that can be achieved with a plasma source that provide continuous operation at the desired power levels of 1 to 2 kilowatts. Over the last two years we have been developing a laboratory prototype to demonstrate the inflation of the magnetic field under space-like conditions. In this paper we will present some of the latest results from the prototype development at the University of Washington and show that the prototype can produce high ionization efficiencies while operating in near space like neutral background pressures producing electron temperatures of a few tens of electron volts. This allows for operation with propellant expenditures lower than originally estimated.

Ziemba, T.

Use of a Prototype Airborne Separation Assurance System for Resolving Near-Term Conflicts During Autonomous Aircraft Operations

NASA is currently investigating a new concept of operations for the National Airspace System, designed to improve capacity while maintaining or improving current levels of safety. This concept, known as Distributed Air/Ground Traffic Management (DAGTM), allows appropriately equipped autonomous aircraft to maneuver freely for flight optimization while resolving conflicts with other traffic and staying out of special use airspace and hazardous weather. In order to perform these tasks, pilots use prototype conflict detection, prevention, and resolution tools, collectively known as an Airborne Separation Assurance System (ASAS). While ASAS would normally allow pilots to resolve conflicts before they become hazardous, evaluation of system performance in sudden, near-term conflicts is needed in order to determine concept feasibility. An experiment was conducted in NASA Langley's Air Traffic Operations Lab to evaluate the prototype ASAS for enabling pilots to resolve near-term conflicts and examine possible operational effects associated with the use of lower separation minimums. Sixteen commercial airline pilots flew a total of 32 traffic scenarios that required them to use prototype ASAS tools to resolve close range pop-up conflicts. Required separation standards were set at either 3 or 5 NM lateral spacing, with 1000 ft vertical separation being used for both cases. Reducing the lateral separation from 5 to 3 NM did not appear to increase operational risk, as indicated by the proximity to the intruder aircraft. Pilots performed better when they followed tactical guidance cues provided by ASAS than when they didn't follow the guidance. In an effort to improve compliance rate, ASAS design changes are currently under consideration. Further studies will of evaluate these design changes and consider integration issues between ASAS and existing Airborne Collision Avoidance Systems (ACAS).

Barhydt, Richard

Preserving the Finger Lakes for the Future: A Prototype Decision Support System for Water Resource Management, Open Space, and Agricultural Protection

This report summarizes the activity conducted under NASA Grant NAG13-02059 entitled "Preserving the Finger Lakes for the Future" A Prototype Decision Support System for Water Resources Management, Open Space and Agricultural Protection, for the period of September 26, 2003 to September 25, 2004. The RACNE continues to utilize the services of its affiliate, the Institute for the Application of Geospatial Technology at Cayuga Community College, Inc. (IAGT), for the purposes of this project under its permanent operating agreement with IAGT. IAGT is a 501(c)(3) not-for-profit Corporation created by the RACNE for the purpose of carrying out its programmatic and administrative mission. The "Preserving the Finger Lakes for the Future" project has progressed and evolved as planned, with the continuation or initiation of a number of program facets at programmatic, technical, and inter-agency levels. The project has grown, starting with the well received core concept of the Virtual Management Operations Center (VMOC), to the functional Watershed Virtual Management Operations Center (W-VMOC) prototype, to the more advanced Finger Lakes Decision Support System (FLDSS) prototype, deployed for evaluation and assessment to a wide variety of agencies and organizations in the Finger Lakes region and beyond. This suite of tools offers the advanced, compelling functionality of interactive 3D visualization interfaced with 2D mapping, all accessed via Internet or virtually any kind of distributed computer network.

Brower, Robert

Development of the Plastic Melt Waste Compactor- Design and Fabrication of the Half-Scale Prototype

A half scale version of a device called the Plastic Melt Waste Compactor prototype has been developed at NASA Ames Research Center to deal with plastic based wastes that are expected to be encountered in future human space exploration scenarios such as Lunar or Martian Missions. The Plastic Melt Waste Compactor design was based on the types of wastes produced on the International Space Station, Space Shuttle, MIR and Skylab missions. The half scale prototype unit will lead to the development of a full scale Plastic Melt Waste Compactor prototype that is representative of flight hardware that would be used on near and far term space missions. This report details the progress of the Plastic Melt Waste Compactor Development effort by the Solid Waste Management group at NASA Ames Research Center.

Pace, Gregory S.

Autobalancing and FDIR for a space-based centrifuge prototype

This report summarizes centrifuge-related work performed at the Smart Systems Research Laboratory at NASA Ames Research Center's Computational Sciences Division from 1995 through 2003. The goal is to develop an automated system that will sense an imbalance (both static and dynamic3) in a centrifuge and issue control commands to drive counterweights to eliminate the effects of the imbalance. This autobalancing development began when the ISS centrifuge design was not yet finalized, and was designed to work with the SSRL Centrifuge laboratory prototype, constructed in 1993-1995. Significant differences between that prototype and the current International Space Station (ISS) Centrifuge design are that: the spin axis for the SSRL Centrifuge prototype can translate freely in x and y, but not wobble, whereas the ISS centrifuge spin axis has 3 translational and two rotational degrees of freedom, supported by a vibration 34. The imbalance sensors are strained gauges both in the rotor and the stator, measuring the imbalance forces, whereas the ISS centrifuge uses eddy current displacement sensors to measure the displacements resulting from imbalance. High fidelity autobalancing and FDIR systems (for both counterweights and strain gauges) are developed and tested in MATLAB simulation, for the SSRL Centrifuge configuration. Hardware implementation of the autobalancing technology was begun in 1996, but was terminated due to lack of funding. The project lay dormant until 2001-2002 when the FDIR capability was added.

Wilson, Edward

Prototype development of a Geostationary Synthetic Thinned Aperture Radiometer (GeoSTAR)

Weather prediction and hurricane tracking would greatly benefit of a continuous imaging capability of a hemisphere at millimeter wave frequencies. We are developing a synthetic thinned aperture radiometer (STAR) prototype operating from 50 to 56 GHz as a ground-based testbed to demonstrate the technologies needed to do full earth disk atmospheric temperature soundings from Geostationary orbit with very high spatial resolution. The prototype consists of a Y-array of 24 MMIC receivers that are compact units implemented with low noise InP MMIC LNAs, second harmonic I-Q mixers, low power IF amplifiers and include internal digital bias control with serial line communication to enable low cost testing and system integration. Furthermore, this prototype STAR includes independent LO and noise calibration signal phase switching circuitry for each arm of the Y-array to verify the operation and calibration of the system.

Millimeter wave low noise amplifiers

Prototype Software for Future Spaceflight Tested at Mars Desert Research Station

NASA scientists in MDRS Crew 49 (April 23-May 7, 2006) field tested and significantly extended a prototype monitoring and advising system that integrates power system telemetry with a voice commanding interface. A distributed, wireless network of functionally specialized agents interacted with the crew to provide alerts (e.g., impending shut-down of inverter due to low battery voltage), access md interpret historical data, and display troubleshooting procedures. In practical application during two weeks, the system generated speech over loudspeakers and headsets lo alert the crew about the need to investigate power system problems. The prototype system adapts the Brahms/Mobile Agents toolkit to receive data from the OneMeter (Brand Electronics) electric metering system deployed by Crew 47. A computer on the upper deck was connected to loudspeakers, four others were paired with wireless (Bluetooth) headsets that enabled crew members to interact with their personal agents from anywhere in the hab. Voice commands and inquiries included: 1. What is the {battery | generator} {volts | amps | volts and amps}? 2. What is the status of the {generator | inverter | battery | solar panel}? 3. What is the hab{itat} {power usage | volts | voltage | amps | volts and amps}? 4. What was the average hab{itat} {amps | volts | voltage} since <#> {AM | PM)? 5. When did the {generator | batteries} change status? 6. Tell {me I | everyone} when{ ever} the generator goes offline. 7. Tell {me | | everyone} when the hab{itat} {amps | volts | voltage} {exceeds | drops brelow} <#>. 8. {Send | Take | Record} {a} voice note {(for | to} } {at }. This research demonstrates the principles of design in the context of use, investigating requirements through experimental use of prototype systems in an analog setting, and use of MDRS as a research facility for designing and implementing new systems.

Clancey, William J.

A One-Piece Lunar Regolith-Bag Garage Prototype

Shelter structures on the moon, even in early phases of exploration, should incorporate lunar materials as much as possible. We designed and constructed a prototype for a one-piece regolith-bag unpressurized garage concept, and, in parallel, we conducted a materials testing program to investigate six candidate fabrics to learn how they might perform in the lunar environment. In our concept, a lightweight fabric form is launched from Earth to be landed on the lunar surface and robotically filled with raw lunar regolith. In the materials testing program, regolith-bag fabric candidates included: VectranTM, NextelTM, Gore PTFE FabricTM, ZylonTM TwaronTM and NomexTM. Tensile (including post radiation exposure), fold, abrasion, and hypervelocity impact testing were performed under ambient conditions, and, within our current means, we also performed these tests under cold and elevated temperatures. In some cases, lunar simulant (JSC-1) was used in conjunction with testing. Our ambition is to continuously refine our testing to reach lunar environmental conditions to the extent possible. A series of preliminary structures were constructed during design of the final prototype. Design is based on the principles of the classic masonry arch. The prototype was constructed of KevlarTM and filled with vermiculite (fairly close to the weight of lunar regolith on the moon). The structure is free-standing, but has not yet been load tested. Our plan for the future would be to construct higher fidelty mockups with each iteration, and to conduct appropriate tests of the structure.

Smithers, Gweneth A.

Extending NASA Research Results to Benefit Society: Rapid Prototyping for Coastal Applications

The mission of the NASA Applied Sciences Program is to expand and accelerate the use of NASA research results to benefit society in 12 application areas of national priority. ONe of the program's major challenges is to perform a quick, efficient, and detailed review (i.e., prototyping) of the large number of combinations of NASA observations and results from Earth system models that may be used by a wide range of decision support tools. A Rapid Prototyping Capacity (RPC) is being developed to accelerate the use of NASA research results. Here, we present the conceptual framework of the Rapid Prototyping Capacity within the context of quickly assessing the efficacy of NASA research results and technologies to support the Coastal Management application. An initial RPC project designed to quickly evaluate the utility of moderate-resolution MODIS products for calibrating/validating coastal sediment transport models is also presented.

Glorioso, Mark V.

Methodology for Prototyping Increased Levels of Automation for Spacecraft Rendezvous Functions

The Crew Exploration Vehicle necessitates higher levels of automation than previous NASA vehicles, due to program requirements for automation, including Automated Rendezvous and Docking. Studies of spacecraft development often point to the locus of decision-making authority between humans and computers (i.e. automation) as a prime driver for cost, safety, and mission success. Therefore, a critical component in the Crew Exploration Vehicle development is the determination of the correct level of automation. To identify the appropriate levels of automation and autonomy to design into a human space flight vehicle, NASA has created the Function-specific Level of Autonomy and Automation Tool. This paper develops a methodology for prototyping increased levels of automation for spacecraft rendezvous functions. This methodology is used to evaluate the accuracy of the Function-specific Level of Autonomy and Automation Tool specified levels of automation, via prototyping. Spacecraft rendezvous planning tasks are selected and then prototyped in Matlab using Fuzzy Logic techniques and existing Space Shuttle rendezvous trajectory algorithms.

Hart, Jeremy J.

Prototype development of a Geostationary Synthetic Thinned Aperture Radiometer, GeoSTAR

Preliminary details of a 2-D synthetic aperture radiometer prototype operating from 50 to 55 GHz will be presented. The laboratory prototype is being developed to demonstrate the technologies and system design needed to do millimeter-wave atmospheric soundings with high spatial resolution from Geostationary orbit. The concept is to deploy a large thinned aperture Y-array on a geostationary satellite, and to use aperture synthesis to obtain images of the Earth without the need for a large mechanically scanned antenna. The laboratory prototype consists of a Y-array of 24 horn antennas, MMIC receivers, and a digital cross-correlation sub-system.

radiometer

IMMR Phase 1 Prototyping Plan Inputs

This viewgraph presentation reviews the phase I plan of the prototype of the IMMR by the Multilateral Medical Operations Panel (MMOP) Medical Informatics & Technology (MIT) Working Group. It reviews the Purpose of IMMR Prototype Phase 1 (IPP1); the IPP1 Plan Overview, the IMMR Prototype Phase 1 Plan for PDDs and MIC and MIC-DDs, Plan for MICs, a nd the IPP1 objectives

Vowell, C. W.

A One-Piece Lunar Regolith-Bag Garage Prototype

Shelter structures on the moon, even in early phases of exploration, should incorporate lunar materials as much as possible. We designed and constructed a prototype for a one-piece regolith-bag unpressurized garage concept, and, in parallel, we conducted a materials testing program to investigate six candidate fabrics to learn how they might perform in the lunar environment. In our concept, a lightweight fabric form is launched from Earth to be landed on the lunar surface and robotically filled with raw lunar regolith. In the materials testing program, regolith-bag fabric candidates included: Vectran(TM), Nextel(TM), Gore PTFE Fabric(TM), Zylon(TM), Twaron(TM), and Nomex(TM). Tensile (including post radiation exposure), fold, abrasion, and hypervelocity impact testing were performed under ambient conditions, and, within our current means, we also performed these tests under cold and elevated temperatures. In some cases, lunar simulant (JSC-1) was used in conjunction with testing. Our ambition is to continuously refine our testing to reach lunar environmental conditions to the extent possible. A series of preliminary structures were constructed during design of the final prototype. Design is based on the principles of the classic masonry arch. The prototype was constructed of Kevlar(TM) and filled with vermiculite (fairly close to the weight of lunar regolith on the moon). The structure is free-standing, but has not yet been load tested. Our plan for the future would be to construct higher fidelity mockups with each iteration, and to conduct appropriate tests of the structure.

Smithers, Gweneth A.

Prototype of NASA's Global Precipitation Measurement Mission Ground Validation System

NASA is developing a Ground Validation System (GVS) as one of its contributions to the Global Precipitation Mission (GPM). The GPM GVS provides an independent means for evaluation, diagnosis, and ultimately improvement of GPM spaceborne measurements and precipitation products. NASA's GPM GVS consists of three elements: field campaigns/physical validation, direct network validation, and modeling and simulation. The GVS prototype of direct network validation compares Tropical Rainfall Measuring Mission (TRMM) satellite-borne radar data to similar measurements from the U.S. national network of operational weather radars. A prototype field campaign has also been conducted; modeling and simulation prototypes are under consideration.

Schwaller, M. R.