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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 127 records · Page 7
All sourcesNASA NTRSDOE OSTI
NASA NTRS2014

Enabling Technologies for Entrepreneurial Opportunities in 3D printing of SmallSats

A consortium of innovative experts in additive manufacturing (AM) comprising Northrup Grumman Technical Services, University of Texas at El Paso (UTEP), Configurable Space Microsystems Innovations & Applications Center (COSMIAC), NASA Glenn Research Center (GRC), and Youngstown State University, have made significant breakthroughs in the goal of creating the first complete 3D printed small satellite. Since AM machines are relatively inexpensive, this should lead to many entrepreneurial opportunities for the small satellite community. Our technology advancements are focused on the challenges of embedding key components within the structure of the article. We have demonstrated, using advanced fused deposition modeling techniques, complex geometric shapes which optimize the spacecraft design. The UTEP Keck Center has developed a method that interrupts the printing process to insert components into specific cavities, resulting in a spacecraft that has minimal internal space allocated for what traditionally were functional purposes. This allows us to increase experiment and instrument capability by provided added volume in a confined small satellite space. Leveraging initial progress made on a NASA contract, the team investigated the potential of new materials that exploit the AM process, producing candidate compositions that exceed the capabilities of traditional materials. These "new materials" being produced and tested include some that have improved radiation shielding, increased permeability, enhanced thermal properties, better conductive properties, and increased structural performance. The team also investigated materials that were previously not possible to be made. Our testing included standard mechanical tests such as vibration, tensile, thermal cycling, and impact resistance as well as radiation and electromagnetic tests. The initial results of these products and their performance will be presented and compared with standard properties. The new materials with the highest probability to disrupt the future of small satellite systems by driving down costs will be highlighted, in conjunction with the electronic embedding process.

Communications↗
NASA NTRS2014

Printed Electronics

Printed electronic device comprising a substrate onto at least one surface of which has been applied a layer of an electrically conductive ink comprising functionalized graphene sheets and at least one binder. A method of preparing printed electronic devices is further disclosed.

Crain, John M.↗
NASA NTRS2015

Printed Electronics

Printed electronic device comprising a substrate onto at least one surface of which has been applied a layer of an electrically conductive ink comprising functionalized graphene sheets and at least one binder. A method of preparing printed electronic devices is further disclosed.

Crain, John M.↗
NASA NTRS2015

Using Additive Manufacturing to Print a CubeSat Propulsion System

CubeSats are increasingly being utilized for missions traditionally ascribed to larger satellites CubeSat unit (1U) defined as 10 cm x 10 cm x 11 cm. Have been built up to 6U sizes. CubeSats are typically built up from commercially available off-the-shelf components, but have limited capabilities. By using additive manufacturing, mission specific capabilities (such as propulsion), can be built into a system. This effort is part of STMD Small Satellite program Printing the Complete CubeSat. Interest in propulsion concepts for CubeSats is rapidly gaining interest-Numerous concepts exist for CubeSat scale propulsion concepts. The focus of this effort is how to incorporate into structure using additive manufacturing. End-use of propulsion system dictates which type of system to develop-Pulse-mode RCS would require different system than a delta-V orbital maneuvering system. Team chose an RCS system based on available propulsion systems and feasibility of printing using a materials extrusion process. Initially investigated a cold-gas propulsion system for RCS applications-Materials extrusion process did not permit adequate sealing of part to make this a functional approach.

electric propulsion systems↗
NASA NTRS2015

Three-Dimensional Printing in Zero Gravity

The 3D printing in zero-g (3D Print) technology demonstration project is a proof-of-concept test designed to assess the properties of melt deposition modeling additive manufacturing in the microgravity environment experienced on the International Space Station (ISS). This demonstration is the first step towards realizing a 'machine shop' in space, a critical enabling component of any deep space mission.

Werkheiser, Niki↗
NASA NTRS2016

Summary Report on Phase I Results from the 3D Printing in Zero G Technology Demonstration Mission, Volume I

Human space exploration to date has been confined to low-Earth orbit and the Moon. The International Space Station (ISS) provides a unique opportunity for researchers to prove out the technologies that will enable humans to safely live and work in space for longer periods of time and venture beyond the Earth/Moon system. The ability to manufacture parts in-space rather than launch them from Earth represents a fundamental shift in the current risk and logistics paradigm for human spaceflight. In September 2014, NASA, in partnership with Made In Space, Inc., launched the 3D Printing in Zero-G technology demonstration mission to explore the potential of additive manufacturing for in-space applications and demonstrate the capability to manufacture parts and tools on orbit using fused deposition modeling. This Technical Publication summarizes the results of testing to date of the ground control and flight prints from the first phase of this ISS payload.

in-space manufacturing↗
NASA NTRS2016

Printed Electronics

Printed electronic device comprising a substrate onto at least one surface of which has been applied a layer of an electrically conductive ink comprising functionalized graphene sheets and at least one binder. A method of preparing printed electronic devices is further disclosed.

Crain, John M.↗
NASA NTRS2018

Printed Electronics

Printed electronic device comprising a substrate onto at least one surface of which has been applied a layer of an electrically conductive ink comprising functionalized graphene sheets and at least one binder. A method of preparing printed electronic devices is further disclosed.

Crain, John M.↗
NASA NTRS2018

3D Printed Structural Core with MMOD Protection

Deep space exploration requires large habitats for both orbital and surface missions. The weight of a habitat is driven largely by its structure and future vehicles require lighter weight structures to minimize launch mass and cost. Unlike honeycomb core materials used in the past, a 3D printed core can be analyzed and optimized for specific load environments, further cutting down mass of the vehicle. Multi-functional structures can integrate features into the primary structure that are traditionally added mass. MMOD (Micro Meteor and Orbital Debris) protection, for example, can be integrated directly into the primary structure of a habitat. This minimizes the mass of the structure and eliminates the need for additional MMOD layers and attachment hardware. This project seeks to develop 3D printed structural core that can be optimized for flights loads and provide integrated MMOD protection.

Hagen, Richard↗
NASA NTRS2018

Three-Dimensional Printing GRCop-42

GRCop-42 (Cu-4 at.% Cr-2 at.% Nb) is a copper (Cu)-chromium (Cr)-niobium (Nb) alloy that NASA developed for use in rocket propulsion components that required high thermal conductivity, excellent creep resistance, low-cycle fatigue life, and strength at elevated temperatures, such as combustion chamber liners and fuel injector face plates. Using powder bed fusion (PBF) 3D printing, NASA Marshall Space Flight Center (MSFC) and NASA Glenn Research Center (GRC) successfully printed near-fully-dense GRCop-42 components that may equal to or exceed their traditionally manufactured predecessors. This Technical Memorandum serves to summarize the process that was developed to achieve 3D printable near-fully-dense and functional GRCop-42.

Cooper, K. G.↗
NASA NTRSDate not supplied

Additively Printed Flexible Temperature Sensor for Wearable Applications

The flexible sensor has the capability to be mounted on any curved surfaces of applications and be used for portable devices. Additively printed sensors have received attention owing to their compact design and ability of application to non-planar surfaces. Wearable applications require capability of integration into a variety of surfaces with ability to flex, fold, twist and stretch under the stresses of daily motion. There is scarcity of data on the interaction of the process parameters with the realized performance. In addition, there is need for data focused on sensor accuracy, repeatability, and reliability. In this study, experimental analysis on function of the fabricated sensing board is conducted. The temperature sensors are made by direct write printing method with nScrypt printer. A calibration of the sensors has been conducted to confirm that resistance is well related to actual temperature and find TCR (temperature coefficient to resistance). The evolution of resistance has been correlated with the environmental temperature. The sensor hysteresis has been quantified using upswing and downswing of the environmental temperature. In addition, the effect of humidity on the temperature sensor accuracy and performance has been quantified. The effect of a polymide coat on the sensor to prevent humidity effects has also been quantified.

Pradeep Lall↗
NASA NTRSDate not supplied

Mechanical Tensile Testing of 3D-Printed Titanium 6Al-4V at Cryogenic Temperature Presentation

- Titanium 6Al-4V is a highly desired material for use in space cryogenics applications. - Structural applications with good strength-to-weight ratios - Thermal isolation applications - Titanium 6Al-4V components can be fabricated via 3D-Printing which can be very beneficial to cryogenic spaceflight components: - 3D-Printing allows parts to be made with geometries and features that are very difficult and sometimes impossible via traditional methods. - Mass savings of components - Increasing structural integrity of components - Increasing thermal isolation and/or conduction of components - Cost savings - Schedule savings

Bryan L James↗
NASA NTRS2024

Metal Extraction from Trash via Trash-to-Gas Processing for Use in 3D Printing

This work synergized state-of-the-art trash-to-gas (TtG) and in-space manufacturing (ISM) technologies to successfully extract metals from astronaut waste items for use in 3D printing. This was accomplished by isolating pure aluminum (Al 1235) from astronaut multilayer food packaging via TtG processing, cleaning the extracted aluminum, and preparing it for compatibility with the bound metal deposition (BMD) 3D printing process. A suite of material analyses was performed on the extracted aluminum product to fully characterize the key properties linked to effective additive manufacturing, including particle size distribution, oxygen content quantitation, and elemental composition. Metal extraction from Lunar and Martian regolith has become a significant area of interest for the in-situ resource utilization (ISRU) community to produce metallic equipment for various mission scenarios. However, the extraction of metals from astronaut waste streams has yet to be investigated. This project demonstrated an end-to-end waste metallic reuse process which may garner considerable metal production that would otherwise be disposed of.

Ray Pitts↗
NASA NTRS2024

Bending Performance of Tungsten Printed Via Laser Powder Bed Fusion With Ceramic Dispersion Modified Powder Feedstock

Additively manufactured tungsten is a candidate refractory material for high-temperature aerospace and nuclear fusion/fission applications. The printability of pure tungsten is challenged by cracking defects arising from the metal’s high brittle-to-ductile transition temperature and low solubility of interstitial impurities. Furthermore, the cast microstructure inherent to the laser powder bed fusion (L-PBF) process has limited strength compared to worked microstructures common in wrought tungsten. Aside from process-related techniques to mitigate defects and increase strength (e.g., heated build chambers, multi-laser systems, low oxygen environmental control, etc.), micro-alloying additions can positively influence tungsten printability and strength. In this work, pure tungsten L-PBF feedstock was modified with 1 wt% additions of ceramic compound nano-powders. Wrought and printed bars were evaluated in four-point bending. Flexural strength and fractography were primary means of comparison to assess the effect of the feedstock modification on printed tungsten mechanical performance.

Additive Manufacturing↗
NASA NTRSDate not supplied

Printed Sensors and Electronics for Sustained Human Spaceflight

As human spaceflight pushes beyond Low Earth Orbit (LEO), resupply of consumables becomes a significant challenge. One solution to this problem is In-Space Manufacturing (ISM), the capability to perform on-demand manufacturing and repair of consumables in an in-space environment. ISM offers significant flexibility to missions as it allows for a high degree of tailorability and reduction in launch mass. Leveraging advancements in fabrication, repair and recycling, ISM provides a highly sustainable and affordable solution to Exploration mission operations and logistics. In this talk, advances in printed electronics and sensors, ranging from nanomaterial ink development and hands-free fabrication methodologies to devices will be presented.

In Space Manufacturing↗