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DOE OSTI2025

Metal additive manufacturing simulation across length, time, and computing scales

Metal additive manufacturing (AM) offers a unique opportunity for production of advanced materials and complex geometries. However, variability in microstructure and properties challenges conventional approaches to design, process optimization, qualification, and materials selection. Modeling and simulation can improve understanding of AM processing and materials, but also poses major challenges for existing computational methods. Simultaneously, modern scientific computing hardware has become increasingly complex, most notably with the adoption of hybrid architectures such as Graphical Processing Units (GPUs). If appropriately utilized, emerging computational capabilities provide an opportunity to reveal new insight into AM processing and the resulting material structure and properties. In this review we describe the computational AM landscape, identify critical gaps, and highlight opportunities to impact the development and application of AM. First, the requirements and challenges of representative AM problem statements will be defined. Here, these problems range from scientific studies to industrial applications and are designed to capture the breadth of challenges facing the AM community. Next, the current state of AM modeling and simulation is evaluated, broken down by enabling hardware and software, process simulation, microstructure simulation, and property simulation. Each section describes the diversity of simulation approaches and associated trade-offs in physical fidelity and computational expense. Each area is then assessed based on their suitability and readiness for current and developing computational architectures. Lastly, the greatest opportunities for future research and application are highlighted, including gaps in modeling capabilities, opportunities for near-term application, and key scientific challenges.

additive manufacturing↗

DOE OSTI2025

Leveraging dendritic complexity for neuromorphic computing

Abstract Beyond-von Neumann computing approaches are necessary to sustain the growth of microelectronics and the increasing appetite for artificial intelligence/machine learning algorithms. Neuromorphic computing is an emerging paradigm that takes inspiration from the brain to provide a path forward to improve the computational efficiency and computational density of next-generation computing architectures. In nature, we observe brains performing complex computations with a much smaller energy footprint than conventional computing approaches. Current neuromorphic systems are focused primarily on scalability, namely, increasing the number of computational units (neurons) and connections between units (synapses). However, for brain-like cognition and efficiency in next-generation computing hardware, we need increased complexity in function, as well as improved connection density for scalability. Here, we present our work that aims to incorporate dendrites for ‘compute-on-wire’ in neuromorphic architectures to increase the computational complexity (e.g. number of programmable parameters, nonlinear dynamics) as well as computational efficiency (energy/compute) of artificial neural networks (ANNs). We do this by showcasing neuromorphic dendrite elements that can be leveraged for various applications. We will present examples of neuroscience-inspired direction-selective circuits and an ANN with active dendrites leveraging shunting inhibition. We also demonstrate the benefits of using dendrites in deep neural networks. To conclude, we discuss how we can utilize emerging hardware devices in these systems and design next-generation neuromorphic architectures with dendrites.

Cardwell, Suma G. (ORCID:0000000226575545)↗

NASA NTRS1984

Software control and system configuration management: A systems-wide approach

A comprehensive software control and system configuration management process for flight-crucial digital control systems of advanced aircraft has been developed and refined to insure efficient flight system development and safe flight operations. Because of the highly complex interactions among the hardware, software, and system elements of state-of-the-art digital flight control system designs, a systems-wide approach to configuration control and management has been used. Specific procedures are implemented to govern discrepancy reporting and reconciliation, software and hardware change control, systems verification and validation testing, and formal documentation requirements. An active and knowledgeable configuration control board reviews and approves all flight system configuration modifications and revalidation tests. This flexible process has proved effective during the development and flight testing of several research aircraft and remotely piloted research vehicles with digital flight control systems that ranged from relatively simple to highly complex, integrated mechanizations.

Petersen, K. L.↗

NASA NTRS1983

Software control and system configuration management - A process that works

Petersen, K. L.↗

NASA NTRS2004

Design Space Issues for Intrinsic Evolvable Hardware

This paper discusses the problem of increased programming time for intrinsic evolvable hardware (EM) as the complexity of the circuit grows. As the circuit becomes more complex, then more components will be required and a longer programming string, L, is required. We develop equations for the size of the population, n, and the number of generations required for the population to converge, based on L. Our analytical results show that even though the design search space grows as 2L (assuming a binary programming string), the number of circuit evaluations, n*ngen, only grows as O(Lg3), or slightly less than O(L). This makes evolvable techniques a good tool for exploring large design spaces. The major hurdle for intrinsic EHW is evaluation time for each possible circuit. The evaluation time involves downloading the bit string to the device, updating the device configuration, measuring the output and then transferring the output data to the control processor. Each of these steps must be done for each member of the population. The processing time of the computer becomes negligible since the selection/crossover/mutation steps are only done once per generation. Evaluation time presently limits intrinsic evolvable hardware techniques to designing only small or medium-sized circuits. To evolve large or complicated circuits, several researchers have proposed using hierarchical design or reuse techniques where submodules are combined together to form complex circuits. However, these practical approaches limit the search space of available designs and preclude utilizing parasitic coupling or other effects within the programmable device. The practical approaches also raise the issue of why intrinsic EHW techniques do not easily apply to large design spaces, since the analytical results show only an O(L) complexity growth.

Hereford, James↗

NASA NTRS1998

Use of an adaptable cell culture kit for performing lymphocyte and monocyte cell cultures in microgravity

The results of experiments performed in recent years on board facilities such as the Space Shuttle/Spacelab have demonstrated that many cell systems, ranging from simple bacteria to mammalian cells, are sensitive to the microgravity environment, suggesting gravity affects fundamental cellular processes. However, performing well-controlled experiments aboard spacecraft offers unique challenges to the cell biologist. Although systems such as the European 'Biorack' provide generic experiment facilities including an incubator, on-board 1-g reference centrifuge, and contained area for manipulations, the experimenter must still establish a system for performing cell culture experiments that is compatible with the constraints of spaceflight. Two different cell culture kits developed by the French Space Agency, CNES, were recently used to perform a series of experiments during four flights of the 'Biorack' facility aboard the Space Shuttle. The first unit, Generic Cell Activation Kit 1 (GCAK-1), contains six separate culture units per cassette, each consisting of a culture chamber, activator chamber, filtration system (permitting separation of cells from supernatant in-flight), injection port, and supernatant collection chamber. The second unit (GCAK-2) also contains six separate culture units, including a culture, activator, and fixation chambers. Both hardware units permit relatively complex cell culture manipulations without extensive use of spacecraft resources (crew time, volume, mass, power), or the need for excessive safety measures. Possible operations include stimulation of cultures with activators, separation of cells from supernatant, fixation/lysis, manipulation of radiolabelled reagents, and medium exchange. Investigations performed aboard the Space Shuttle in six different experiments used Jurkat, purified T-cells or U937 cells, the results of which are reported separately. We report here the behaviour of Jurkat and U937 cells in the GCAK hardware in ground-based investigations simulating the conditions expected in the flight experiment. Several parameters including cell concentration, time between cell loading and activation, and storage temperature on cell survival were examined to characterise cell response and optimise the experiments to be flown aboard the Space Shuttle. Results indicate that the objectives of the experiments could be met with delays up to 5 days between cell loading into the hardware and initial in flight experiment activation, without the need for medium exchange. Experiment hardware of this kind, which is adaptable to a wide range of cell types and can be easily interfaced to different spacecraft facilities, offers the possibility for a wide range of experimenters successfully and easily to utilise future flight opportunities.

short duration↗

NASA NTRS2013

Applications for Gradient Metal Alloys Fabricated Using Additive Manufacturing

Recently, additive manufacturing (AM) techniques have been developed that may shift the paradigm of traditional metal production by allowing complex net-shaped hardware to be built up layer-by-layer, rather than being machined from a billet. The AM process is ubiquitous with polymers due to their low melting temperatures, fast curing, and controllable viscosity, and 3D printers are widely available as commercial or consumer products. 3D printing with metals is inherently more complicated than with polymers due to their higher melting temperatures and reactivity with air, particularly when heated or molten. The process generally requires a high-power laser or other focused heat source, like an electron beam, for precise melting and deposition. Several promising metal AM techniques have been developed, including laser deposition (also called laser engineered net shaping or LENS® and laser deposition technology (LDT)), direct metal laser sintering (DMLS), and electron beam free-form (EBF). These machines typically use powders or wire feedstock that are melted and deposited using a laser or electron beam. Complex net-shape parts have been widely demonstrated using these (and other) AM techniques and the process appears to be a promising alternative to machining in some cases. Rather than simply competing with traditional machining for cost and time savings, the true advantage of AM involves the fabrication of hardware that cannot be produced using other techniques. This could include parts with "blind" features (like foams or trusses), parts that are difficult to machine conventionally, or parts made from materials that do not exist in bulk forms. In this work, the inventors identify that several AM techniques can be used to develop metal parts that change composition from one location in the part to another, allowing for complete control over the mechanical or physical properties. This changes the paradigm for conventional metal fabrication, which relies on an assortment of "post-processing" methods to locally alter properties (such as coating, heat treating, work hardening, shot peening, etching, anodizing, among others). Building the final part in an additive process allows for the development of an entirely new class of metals, so-called "functionally graded metals" or "gradient alloys." By carefully blending feedstock materials with different properties in an AM process, hardware can be developed with properties that cannot be obtained using other techniques but with the added benefit of the net-shaped fabrication that AM allows.

Hofmann, Douglas C.↗

NASA NTRS2022

Robotics Verification and Validation Strategies for Perseverance Rover Sampling and Caching

The Mars 2020 Sampling and Caching Subsystem(SCS) is the most complex robotic system ever fielded on a MarsRover. It includes a 5 degree-of-freedom Robotic Arm, coringdrill, gas Dust Removal Tool, interfaces for two turret-mountedinstruments, and an Adaptive Caching Assembly (ACA). TheACA is itself a complex robotic system, containing hardware tosupport docking and bit exchange, a 3 degree-of-freedomSample Handling Assembly for manipulating sample tubes,storage for several drill bits and sample tubes, and mechanismsto support observing and sealing samples collected by the drill.To successfully verify and validate the SCS hardware andsoftware and its integration with the Mars 2020 flight systemseveral key strategies were employed.The SCS Verification and Validation (V&V) program utilizedmultiple test venues with tiered levels of fidelity. These includedsimulation and visualization software environments, low fidelitydevelopment testbeds, testbeds with high fidelity SCS hardwareand commercial off-the shelf avionics, integrated systemtestbeds with flight-like avionics, and environmental testbedscapable of simulating Martian surface temperature andpressure. Multiple units of each SCS hardware componentmoved fluidly between test venues to accomplish myriadstandalone and coordinated test objectives. Test preparationand executions were performed by a diverse team of engineerswith training and technical ownership tailored for individualexperience and role. Despite significant differences between testvenues, the SCS V&V team established efficient and consistentprocesses and tools for procedure development, test execution,and data review that enabled personnel, as well as technicalproducts such as sequences and parameter configurations, toflow between venues effectively. A series of benchmark testsprovided evidence of performance consistency as elements weretransferred between venues and as system capability evolved.This paper provides an overview of the SCS V&V program andexplores several overarching strategies that enabled successfuloperation in the face of unprecedented complexity. Keyoutcomes of the SCS validation effort are summarized, alongwith lessons learned and beneficial integrations of validationtool and process innovations into Mars surface operations.

Brooks, Sawyer↗

DOE OSTI2025

Fourier-based three-dimensional multistage transformer for aberration correction in multicellular specimens

High-resolution tissue imaging is often compromised by sample-induced optical aberrations that degrade resolution and contrast. Although wavefront sensor-based adaptive optics (AO) can measure these aberrations, such hardware solutions are typically complex, expensive to implement and slow when serially mapping spatially varying aberrations across large fields of view. Here we introduce AOViFT (adaptive optical vision Fourier transformer)—a machine learning-based aberration sensing framework built around a three-dimensional multistage vision transformer that operates on Fourier domain embeddings. AOViFT infers aberrations and restores diffraction-limited performance in puncta-labeled specimens with substantially reduced computational cost, training time and memory footprint compared to conventional architectures or real-space networks. We validated AOViFT on live gene-edited zebrafish embryos, demonstrating its ability to correct spatially varying aberrations using either a deformable mirror or postacquisition deconvolution. By eliminating the need for the guide star and wavefront sensing hardware and simplifying the experimental workflow, AOViFT lowers technical barriers for high-resolution volumetric microscopy across diverse biological samples.

Alshaabi, Thayer [Howard Hughes Medical Institute,↗

NASA NTRS2016

Assessment of the Impacts of ACLS on the ISS Life Support System Using Dynamic Simulations in V-HAB

The Advanced Closed Loop System (ACLS) is currently under development by Airbus Defense and Space and is slated for launch to the International Space Station (ISS) in 2017. The addition of new hardware into an already complex system such as the ISS life support system (LSS) always poses operational risks. It is therefore important to understand the impacts ACLS will have on the existing systems to ensure smooth operations for the ISS. This analysis can be done by using dynamic computer simulations and one possible tool for such a simulation is the Virtual Habitat (V-HAB). Based on MATLAB, V-HAB has been under development at the Institute of Astronautics of the Technical University of Munich (TUM) since 2004 and in the past has been successfully used to simulate the ISS life support systems. The existing V-HAB ISS simulation model treated the interior volume of the space station as one large, ideally-stirred container. This model was improved to allow the calculation of the atmospheric composition inside individual modules of the ISS by splitting it into twelve distinct volumes. The virtual volumes are connected by a simulation of the inter-module ventilation flows. This allows for a combined simulation of the LSS hardware and the atmospheric composition aboard the ISS. A dynamic model of ACLS is added to the ISS Simulation and several different operating modes for both ACLS and the existing ISS life support systems are studied and the impacts of ACLS on the rest of the system are determined. The results suggest that the US, Russian and ACLS CO2 systems can operate at the same time without impeding each other. Furthermore, based on the results of this analysis, the US and ACLS Sabatier systems can be operated in parallel as well to a achieve a very low CO2 concentration in the cabin atmosphere.

Putz, Daniel↗

NASA NTRS2016

Assessment of the Impacts of ACLS on the ISS Life Support System using Dynamic Simulations in V-HAB

The Advanced Closed Loop System (ACLS) is currently under development by Airbus Defense and Space and is slated for launch to the International Space Station (ISS) in 2017. The addition of new hardware into an already complex system such as the ISS life support system (LSS) always poses operational risks. It is therefore important to understand the impacts ACLS will have on the existing systems to ensure smooth operations for the ISS. This analysis can be done by using dynamic computer simulations and one possible tool for such a simulation is Virtual Habitat (V-HAB). Based on Matlab (Registered Trademark) V-HAB has been under development at the Institute of Astronautics of the Technical University Munich (TUM) since 2006 and in the past has been successfully used to simulate the ISS life support systems. The existing V-HAB ISS simulation model treated the interior volume of the space station as one large ideally-stirred container. This model was improved to allow the calculation of the atmospheric composition inside the individual modules of the ISS by splitting it into ten distinct volumes. The virtual volumes are connected by a simulation of the inter-module ventilation flows. This allows for a combined simulation of the LSS hardware and the atmospheric composition aboard the ISS. A dynamic model of ACLS is added to the ISS simulation and different operating modes for both ACLS and the existing ISS life support systems are studied to determine the impacts of ACLS on the rest of the system. The results suggest that the US, Russian and ACLS CO2 systems can operate at the same time without impeding each other. Furthermore, based on the results of this analysis, the US and ACLS Sabatier systems can be operated in parallel as well to achieve the highest possible CO2 recycling together with a low CO2 concentration.

Puetz, Daniel↗

NASA NTRSDate not supplied

Microbial Methods for Testing a Novel Spacecraft Bioburden Reduction Method

In order to circumvent the contamination of microorganisms in both extraterrestrial and terrestrial environments, spacecraft hardware must often be sterilized. Current sterilization practices are both time-consuming and expensive. Techniques such as dry heat sterilization and scattered/localized electric field enhancements are incompatible with a variety of hardware materials as well as complex surface shapes. Our group is testing a novel femtosecond pulsed laser for the rapid sterilization of spacecraft hardware using high photon fluxes, which is both an efficient and effective technique to ensure a reduced microbial burden aboard spacecraft. This method is likely to be effective because microorganisms have not encountered high photon fluxes in their evolutionary history and thus contain no protective mechanisms against them. To assess the effectiveness of pulsed laser sterilization, we used a combination of scanning electron microscopy and elemental analysis for the examination of damaged spores on metal coupons, as well as microbiology methods for spore assays. The surfaces of metal coupons inoculated with Bacillus subtilis were illuminated with femtosecond pulses at various wavelengths below the damage threshold for the aluminum. After laser treatment, metal coupon samples were sonicated to dislodge spores, serially diluted, and finally plated and incubated. Results show that sterilization efficiency is favorable in some conditions. The NASA standards for spore assays are a preliminary demonstration in establishing the trend in ability to kill spores. The results show potential for the dual pulse illumination method as a sterilization technique for planetary protection applications.

Maha S Ulhaq↗

DOE OSTI2025

High-power test of a C-band linear accelerating structure with an RFSoC-based LLRF system

Normal conducting linear particle accelerators consist of multiple rf stations with accelerating structure cavities. Low-level rf (LLRF) systems are employed to set the phase and amplitude of the field in the accelerating structure and to compensate for the pulse-to-pulse fluctuation of the rf field in the accelerating structures with a feedback loop. The LLRF systems are typically implemented with analog rf mixers, heterodyne-based architectures, and discrete data converters. There are multiple rf signals from each of the rf stations, so the number of rf channels required increases rapidly with multiple rf stations. With a large number of rf channels, the footprint, component cost, and system complexity of the LLRF hardware will increase significantly. To meet the design goals of being compact and affordable for future accelerators, we have designed the next-generation LLRF (NG-LLRF) with a higher integration level based on RFSoC technology. The NG-LLRF system samples rf signals directly and performs rf mixing digitally. Further, the NG-LLRF has been characterized in loopback mode to evaluate the performance of the system and has also been tested with a standing-wave accelerating structure, a prototype for the Cool Copper Collider (C 3 ) with a peak rf power level up to 16.45 MW. The loopback test demonstrated amplitude fluctuation below 0.15% and phase fluctuation below 0.15°, which are considerably better than the requirements of C 3 . The rf signals from the different stages of the accelerating structure at different power levels are measured by the NG-LLRF, which will be critical references for the control algorithm designs. The NG-LLRF also offers flexibility in waveform modulation, so we have used rf pulses with various modulation schemes, which could be useful for controlling some of the rf stations in accelerators. In this paper, the high-power test results at different stages of the test setup will be summarized, analyzed, and discussed.

47 OTHER INSTRUMENTATION↗

NASA NTRS1977

Direct-connect test of a hydrogen-fueled three-strut injector for an integrated modular scramjet engine

The study aims at illustrating the effects of strut and injector interactions and strut wakes not totally simulated in previous, less complex, direct-connect hardware. In addition, the influence of the relative location of the injectors on opposite sides of each strut and the effect of injector spacing are evaluated. It is shown that better mixing efficiency is attained by locating the fuel injectors on opposite sides of a strut so that the jets come together, rather than being staggered, in the strut wake. It is not possible to determine the combustion efficiency by means of a one-dimensional analysis of the wall pressure.

Mcclinton, C. R.↗

NASA NTRS1979

Spacecraft attitude and articulation control systems for future planetary missions

Comparative evaluations of the major types of control systems, such as three-axis-active, spin-stabilized, dual spin, and momentum basis, are performed to determine their applicability for planetary missions in the early 1990s. The key requirements that determine control system selection are science functional, mission orbital, and vehicle configuration characteristics. Five functional groups are given for preliminary control system selection: (1) preliminary survey; (2) detailed remote observation; (3) close scrutiny - deep space; (4) close scrutiny - near sun; (5) sample return. Requirements affecting the selection of attitude/articulation control methods, comparison of the performance capabilities of competing control concepts, criteria for selecting competing methods, comparison of relative complexity, and identification of hardware needs and trends that may affect control system selection are considered.

Mcglinchey, L. F.↗

NASA NTRS1980

Turbine blade structural dynamic analysis

The paper presents structural dynamic analysis and test results for the Space Shuttle Main Engine turbine blades. Athough these blades are designed to avoid coincidence of natural frequencies with harmonic excitation forces, the complexity of the turbine hardware, its nonlinearities and lack of information regarding the forcing function have led to fatigue failures. A comparison of single-blade analysis and test modal frequencies, shapes, and stresses is given; analysis techniques to describe the forcing function, compute dynamic responses, and incorporate the nonlinearities of Coulomb-friction dampers are presented. Recommendations are made for new research to improve forcing function computations and structural damping estimates used in the analysis.

Dickerson, E. O.↗

NASA NTRS1989

Parallel processing environment for multi-flexible body dynamics

The implementation of a dynamics solution algorithm with inherent parallelism which is applicable to the dynamics of large flexible space structures is described. The algorithm is unique in that parts of the solution can be computed simultaneously by working with different branches of its tree topology. The algorithm exhibits close to 0(n) type behavior. The data flow within the solution algorithm is discussed along with results from its implementation in a multiprocessing environment. A model of the United States Space Station is used as an example. The results show that, with fast multiple scalar processors, an efficient algorithm, and symbolically generated equations of motion, real-time performance can be achieved with present-day hardware technology, even with complex dynamical models.

Venugopal, Ravi↗

NASA NTRS1990

Modeling reality

Although powerful computers have allowed complex physical and manmade hardware systems to be modeled successfully, we have encountered persistent problems with the reliability of computer models for systems involving human learning, human action, and human organizations. This is not a misfortune; unlike physical and manmade systems, human systems do not operate under a fixed set of laws. The rules governing the actions allowable in the system can be changed without warning at any moment, and can evolve over time. That the governing laws are inherently unpredictable raises serious questions about the reliability of models when applied to human situations. In these domains, computers are better used, not for prediction and planning, but for aiding humans. Examples are systems that help humans speculate about possible futures, offer advice about possible actions in a domain, systems that gather information from the networks, and systems that track and support work flows in organizations.

Denning, Peter J.↗