Search NASA⌕ Search

SEARCH · Search NASA

Results for “Polypropylene”

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.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 163 records · Page 9
All sourcesNASA NTRSDOE OSTI
NASA NTRS2009

Hollow Fiber Space Suit Water Membrane Evaporator Development for Lunar Missions

The Space Suit Water Membrane Evaporator (SWME) is the baseline heat rejection technology selected for development for the Constellation lunar suit. The Hollow Fiber (HoFi) SWME is being considered for service in the Constellation Space Suit Element (CSSE) Portable Life Support Subsystem (PLSS) to provide cooling to the thermal loop through water evaporation to the vacuum of space. Previous work described the test methodology and planning to compare the test performance of three commercially available hollow fiber materials as alternatives to the sheet membrane prototype for SWME: 1) porous hydrophobic polypropylene, 2) porous hydrophobic polysulfone, and 3) ion exchange through nonporous hydrophilic modified Nafion. Contamination tests were performed to probe for sensitivities of the candidate SWME elements to organics and non-volative inorganics expected to be found in the target feedwater source, i.e., potable water provided by the vehicle. The resulting presence of precipitate in the coolant water could plug pores and tube channels and affect the SWME performance. From this prior work, a commercial porous hydrophobic hollow fiber was selected to satisfy both the sensitivity question and the need to provide 800 W of heat rejection. This paper describes the trade studies, the design methodology, and the hollow fiber test data used to design a full

Bue, Grant C.↗
NASA NTRS2010

Detecting strain in birefringent materials using spectral polarimetry

A method, computer program product and system for analyzing multispectral images from a plurality of regions of birefringent material, such as a polymer film, using polarized light and a corresponding polar analyzer to identify differential strain in the birefringent material. For example, the birefringement material may be low-density polyethylene (LDPE), high-density polyethylene (HDPE), polypropylene, polyethylene terephthalate (PET), polyvinyl chloride (PVC), polyvinylidene chloride, polyester, nylon, or cellophane film. Optionally, the method includes generating a real-time quantitative strain map.

Ragucci, Anthony J.↗
NASA NTRS2011

Disinfection of Spacecraft Potable Water Systems by Photocatalytic Oxidation Using UV-A Light Emitting Diodes

Ultraviolet (UV) light has long been used in terrestrial water treatment systems for photodisinfection and the removal of organic compounds by several processes including photoadsorption, photolysis, and photocatalytic oxidation/reduction. Despite its effectiveness for water treatment, UV has not been explored for spacecraft applications because of concerns about the safety and reliability of mercury-containing UV lamps. However, recent advances in ultraviolet light emitting diodes (UV LEDs) have enabled the utilization of nanomaterials that possess the appropriate optical properties for the manufacture of LEDs capable of producing monochromatic light at germicidal wavelengths. This report describes the testing of a commercial-off-the-shelf, high power Nichia UV-A LED (250mW A365nnJ for the excitation of titanium dioxide as a point-of-use (POD) disinfection device in a potable water system. The combination of an immobilized, high surface area photocatalyst with a UV-A LED is promising for potable water system disinfection since toxic chemicals and resupply requirements are reduced. No additional consumables like chemical biocides, absorption columns, or filters are required to disinfect and/or remove potentially toxic disinfectants from the potable water prior to use. Experiments were conducted in a static test stand consisting of a polypropylene microtiter plate containing 3mm glass balls coated with titanium dioxide. Wells filled with water were exposed to ultraviolet light from an actively-cooled UV-A LED positioned above each well and inoculated with six individual challenge microorganisms recovered from the International Space Station (ISS): Burkholderia cepacia, Cupriavidus metallidurans, Methylobacterium fujisawaense, Pseudomonas aeruginosa, Sphingomonas paucimobilis and Wautersia basilensis. Exposure to the Nichia UV-A LED with photocatalytic oxidation resulted in a complete (>7-log) reduction of each challenge bacteria population in <180 minutes of contact time. With continued advances in the design and manufacture of UV-A LEDs and semi-conducting photocatalysts, LED activated photochemical process technology promises to extend its application to spacecraft environmental systems.

Birmele, Michele N.↗
NASA NTRS2004

Module for Oxygenating Water without Generating Bubbles

A module that dissolves oxygen in water at concentrations approaching saturation, without generating bubbles of oxygen gas, has been developed as a prototype of improved oxygenators for water-disinfection and water-purification systems that utilize photocatalyzed redox reactions. Depending on the specific nature of a water-treatment system, it is desirable to prevent the formation of bubbles for one or more reasons: (1) Bubbles can remove some organic contaminants from the liquid phase to the gas phase, thereby introducing a gas-treatment problem that complicates the overall water-treatment problem; and/or (2) in some systems (e.g., those that must function in microgravity or in any orientation in normal Earth gravity), bubbles can interfere with the flow of the liquid phase. The present oxygenation module (see Figure 1) is a modified version of a commercial module that contains >100 hollow polypropylene fibers with a nominal pore size of 0.05 m and a total surface area of 0.5 m2. The module was originally designed for oxygenation in a bioreactor, with no water flowing around or inside the tubes. The modification, made to enable the use of the module to oxygenate flowing water, consisted mainly in the encapsulation of the fibers in a tube of Tygon polyvinyl chloride (PVC) with an inside diameter of 1 in. (approx.=25 mm). In operation, water is pumped along the insides of the hollow fibers and oxygen gas is supplied to the space outside the hollow tubes inside the PVC tube. In tests, the pressure drops of water and oxygen in the module were found to be close to zero at water-flow rates ranging up to 320 mL/min and oxygen-flow rates up to 27 mL/min. Under all test conditions, no bubbles were observed at the water outlet. In some tests, flow rates were chosen to obtain dissolved-oxygen concentrations between 25 and 31 parts per million (ppm) . approaching the saturation level of approx.=35 ppm at a temperature of 20 C and pressure of 1 atm (approx.=0.1 MPa). As one would expect, it was observed that the time needed to bring a flow of water from an initial low dissolved-oxygen concentration (e.g., 5 ppm) to a steady high dissolved-oxygen concentration at or near the saturation level depends on the rates of flow of both oxygen and water, among other things. Figure 2 shows the results of an experiment in which a greater flow of oxygen was used during the first few tens of minutes to bring the concentration up to approx.=25 ppm, then a lesser flow was used to maintain the concentration.

Gonzalez-Martin, Anuncia↗
NASA NTRS2013

Cosmo Cassette: A Microfluidic Microgravity Microbial System For Synthetic Biology Unit Tests and Satellite Missions

Although methods in the design-build-test life cycle of the synthetic biology field have grown rapidly, the expansion has been non-uniform. The design and build stages in development have seen innovations in the form of biological CAD and more efficient means for building DNA, RNA, and other biological constructs. The testing phase of the cycle remains in need of innovation. Presented will be both a theoretical abstraction of biological measurement and a practical demonstration of a microfluidics-based platform for characterizing synthetic biological phenomena. Such a platform demonstrates a design of additive manufacturing (3D printing) for construction of a microbial fuel cell (MFC) to be used in experiments carried out in space. First, the biocompatibility of the polypropylene chassis will be demonstrated. The novel MFCs will be cheaper, and faster to make and iterate through designs. The novel design will contain a manifold switchingdistribution system and an integrated in-chip set of reagent reservoirs fabricated via 3D printing. The automated nature of the 3D printing yields itself to higher resolution switching valves and leads to smaller sized payloads, lower cost, reduced power and a standardized platform for synthetic biology unit tests on Earth and in space. It will be demonstrated that the application of unit testing in synthetic biology will lead to the automatic construction and validation of desired constructs. Unit testing methodologies offer benefits of preemptive problem identification, change of facility, simplicity of integration, ease of documentation, and separation of interface from implementation, and automated design.

Bioelectrochemical System↗
NASA NTRS2015

Enhanced Polyhydroxybutyrate Production for Long-Term Spaceflight Applications

Synthetic biology holds the promise of advancing long term space fight by the production of medicine, food, materials, and energy. One such application of synthetic biology is the production of biomaterials, specifically polyhydroxyalkanoates (PHAs), using purposed organisms such as Escherichia coli. PHAs are a group of biodegradable bioplastics that are produced by a wide variety of naturally occurring microorganisms, mainly as an energy storage intermediate. PHAs have similar melting point to polypropylene and a Youngs modulus close to polystyrene. Due to limited resources and cost of transportation, large-scale extraction of biologically produced products in situ is extremely cumbersome during space flight. To that end, we are developing a secretion systems for exporting PHA from the cell in order to reduce unit operations. PHAs granules deposited inside bacteria are typically associated with proteins bound to the granule surface. Phasin, a granule bound protein, was targeted for type I secretion by fusion with HlyA signal peptide for indirect secretion of PHAs. In order to validate our secretion strategy, a green fluorescent protein (GFP) was tagged to the PHA polymerase enzyme (phaC), this three part gene cassette consists of phaA and phaB and are required for PHA production. Producing PHAs in situ during space flight or planet colonization will enable mission success by providing a valuable source of biomaterials that can have many potential applications thereby reducing resupply requirements. Biologically produced PHAs can be used in additive manufacturing such as three dimensional (3D) printing to create products that can be made on demand during space flight. After exceeding their lifetime, the PHAs could be melted and recycled back to 3D print other products. We will discuss some of our long term goals of this approach.

In Situ↗
NASA NTRS2016

Mechanical Model Development for Composite Structural Supercapacitors

Novel composite structural supercapacitor concepts have recently been developed as a means both to store electrical charge and to provide modest mechanical load carrying capability. Double-layer composite supercapacitors are often fabricated by impregnating a woven carbon fiber fabric, which serves as the electrodes, with a structural polymer electrolyte. Polypropylene or a glass fabric is often used as the separator material. Recent research has been primarily limited to evaluating these composites experimentally. In this study, mechanical models based on the Multiscale Generalized Method of Cells (MSGMC) were developed and used to calculate the shear and tensile properties and response of two composite structural supercapacitors from the literature. The modeling approach was first validated against traditional composite laminate data. MSGMC models for composite supercapacitors were developed, and accurate elastic shear/tensile properties were obtained. It is envisioned that further development of the models presented in this work will facilitate the design of composite components for aerospace and automotive applications and can be used to screen candidate constituent materials for inclusion in future composite structural supercapacitor concepts.

Micromechanics↗
NASA NTRS2017

A UAV-Based Fog Collector Design for Fine-Scale Aerobiological Sampling

Airborne microbes are found throughout the troposphere and into the stratosphere. Knowing how the activity of airborne microorganisms can alter water, carbon, and other geochemical cycles is vital to a full understanding of local and global ecosystems. Just as on the land or in the ocean, atmospheric regions vary in habitability; the underlying geochemical, climatic, and ecological dynamics must be characterized at different scales to be effectively modeled. Most aerobiological studies have focused on a high level: 'How high are airborne microbes found?' and 'How far can they travel?' Most fog and cloud water studies collect from stationary ground stations (point) or along flight transects (1D). To complement and provide context for this data, we have designed a UAV-based modified fog and cloud water collector to retrieve 4D-resolved samples for biological and chemical analysis.Our design uses a passive impacting collector hanging from a rigid rod suspended between two multi-rotor UAVs. The suspension design reduces the effect of turbulence and potential for contamination from the UAV downwash. The UAVs are currently modeled in a leader-follower configuration, taking advantage of recent advances in modular UAVs, UAV swarming, and flight planning.The collector itself is a hydrophobic mesh. Materials including Tyvek, PTFE, nylon, and polypropylene monofilament fabricated via laser cutting, CNC knife, or 3D printing were characterized for droplet collection efficiency using a benchtop atomizer and particle counter. Because the meshes can be easily and inexpensively fabricated, a set can be pre-sterilized and brought to the field for 'hot swapping' to decrease cross-contamination between flight sessions or use as negative controls.An onboard sensor and logging system records the time and location of each sample; when combined with flight tracking data, the samples can be resolved into a 4D volumetric map of the fog bank. Collected samples can be returned to the lab for a variety of analyses. Based on a review of existing flight studies, we have identified ion chromatography, metagenomic sequencing, cell staining and quantification, and ATP quantification as high-priority assays for implementation. Support for specific toxicology assays, such as methylmercury quantification, is also planned.

Design↗
NASA NTRS2018

Characterizing Material Scalability for Ultralight Lattice Design

Stiff yet ultra-light lattice structures constructed using digital materials have many practical applications as the building block for aircraft and other structures. By furthering our understanding of how material configuration affects the structural properties of an ultralight lattice, we can intelligently design these structures based on their intended function. Here we compare the behavior of ultralight lattice structures when fabricated by different materials. The individual unit cells of the lattice structures are referred to as voxels. The stiffness, elastic modulus, and yield strength of the specimens in compression and tension are determined through mechanical testing. Specimens are tested both as single voxel as well as 4x4x4 voxel constructions on an Instron 5982 Universal Testing System until failure. Each voxel is manufactured in bulk through injection molding, with a unit cell pitch of 76.2 mm. Individual voxels are fastened with machine screws and nuts to create assemblies. Four separate materials are used as voxel compositions in this experiment. These include a homogeneous polymer referred to as Ultem 1000, a glass-fiber reinforced polymer referred to as Ultem 2200, a polymer with chopped carbon fibers as 30% of its fill, and homogenous polypropylene. This work compares mechanical behavior, as well as the convergence behavior of the lattice as the size of the lattice assembly increases for various materials. The goal of this study is to characterize the behavior of homogenous lattices such that heterogenous lattices can be designed with different material voxels to achieve target material properties for ultralight space applications.

Sajjadi, Afsheen↗
NASA NTRS2018

An Improved UAV-Based Fog Collector for Local-Scale Aerobiological Sampling

The use of unmanned air vehicles (UAVs) to passively collect fog for microbiological analysis is being investigated at NASA Ames, contributing to our understanding of the dynamics and limits of the biosphere. Current improvements to a preliminary payload design include physically modifying the mesh of the passive impactor collection unit (PICU) to increase fog-capture efficiency and a quick- mounting system to improve sample turnaround and contamination control. Increasing the water-capture efficiency of the PICU involved changing the surface roughness of the polypropylene mesh by abrasive sanding. Four scale models of the PICU were created, with three of those models sanded with 80-, 150-, and 240-grit sand paper for a minimum of thirty seconds on each side. Each mesh was individually tested in a fog-simulation chamber to measure collection efficiency. Tests showed that sanding the mesh will increase the water-capture efficiency by at least 3-fold for the 150- and 240-grit. Next steps are to determine the scaling laws and minimum amount of exposure time as a function of the fog density, to acquire enough microorganisms for analysis; a light-weight ground module for the PICU has been developed to allow rapid, easy field testing. Developing a mounting system that will ensure sterile deployment, as well as prompt changes of PICUs, for collection of fog water, utilized computational fluid dynamics (CFD) for the UAV to ensure that the location of the impactors will not be contaminated by particulates in the UAV downwash. The original design allowed the impactors to remain within sterile packaging until mounted on the UAV but did not address the concerns of contamination from aerodynamic ground effects and particulate lofting during takeoff. Design for a raised launch pad would allow for the sterile PICU to be attached to UAV and launched from outside the region of projected particulate lofting. California coastal sites have been scouted for appropriate testing locations. The improvements to the PICU design and operations will allow for multiple sampling points within a single fog event. The returned fog samples will undergo ion chromatography, qPCR, ATP quantification, and other tests to characterize microbial species and relevant biochemistry.

Wong, Amber↗
NASA NTRS2016

A UAV-Based Fog Collector Design for Fine-Scale Aerobiological Sampling

Airborne microbes are found throughout the troposphere and into the stratosphere. Knowing how the activity of airborne microorganisms can alter water, carbon, and other geochemical cycles is vital to a full understanding of local and global ecosystems. Just as on the land or in the ocean, atmospheric regions vary in habitability; the underlying geochemical, climatic, and ecological dynamics must be characterized at different scales to be effectively modeled. Most aerobiological studies have focused on a high level: 'How high are airborne microbes found?' and 'How far can they travel?' Most fog and cloud water studies collect from stationary ground stations (point) or along flight transects (1D). To complement and provide context for this data, we have designed a UAV-based modified fog and cloud water collector to retrieve 4D-resolved samples for biological and chemical analysis.Our design uses a passive impacting collector hanging from a rigid rod suspended between two multi-rotor UAVs (Unmanned Aerial Vehicles). The suspension design reduces the effect of turbulence and potential for contamination from the UAV downwash. The UAVs are currently modeled in a leader-follower configuration, taking advantage of recent advances in modular UAVs, UAV swarming, and flight planning.The collector itself is a hydrophobic mesh. Materials including Tyvek, PTFE, nylon, and polypropylene monofilament fabricated via laser cutting, CNC knife, or 3D printing were characterized for droplet collection efficiency using a benchtop atomizer and particle counter. Because the meshes can be easily and inexpensively fabricated, a set can be pre-sterilized and brought to the field for 'hot swapping' to decrease cross-contamination between flight sessions or use as negative controls.An onboard sensor and logging system records the time and location of each sample; when combined with flight tracking data, the samples can be resolved into a 4D volumetric map of the fog bank. Collected samples can be returned to the lab for a variety of analyses. Based on a review of existing flight studies, we have identified ion chromatography, metagenomic sequencing, cell staining and quantification, and ATP quantification as high-priority assays for implementation. Support for specific toxicology assays, such as methyl-mercury quantification, is also planned.

Design↗
NASA NTRS2019

Cleanroom Contamination Identification Method Development

During fabrication, assembly, and testing of spacecraft and flight hardware it is vital to avoid contaminants that can cause degradation and could result in significant failure. Yet, there is no existing contamination monitoring method that provides the identity of airborne particles in a cleanroom facility. Knowing the particle identities, would allow scientists and engineers to determine the source of the contaminants and prevent setbacks before they occur or cause damage. Current cleanliness monitoring methods include airborne particle counters (APCs), fallout filters, and visual inspections. Particle counts from APCs are the primary metric used to define a cleanroom class and hence its level of cleanliness, but do not provide identification nor can they differentiate between large and small sizes of particles. In addition, using fallout filters is not a proactive, timely, or representative approach to cleanroom contamination monitoring because these samples are only retrieved after 30 days and are placed away from spacecraft processing to avoid interference with operations. In contrast, the forced air sampling method can collect a sample within an hour at any location required and provide results in less than a day. This system uses a cassette and filter sample medium to capture airborne particles which are then taken to a scanning electron microscope with energy dispersive spectroscopy (SEM/EDS) to identify and size the captured particles. Development of forced air sampling into an established laboratory capability will allow for fast sampling and routine identification of unknown contamination sources within the cleanroom. The test method development required market research for an air sampling cassette that increases sample collection efficiency and a filter with low enough background contamination to allow differentiation between a blank (control) and the collected sample. It was determined that a conductive black cassette and a polycarbonate filter were the best options. Conductive black cassettes, in comparison to the standard styrene, are manufactured using polypropylene filled with carbon. This makes the cassette conductive and minimizes the tendency of particles to stick to the wall of the cassette due to electrostatic force. In previous trials a mixed cellulose ester (MCE) filter was used to capture the contaminants, however the rougher surface of the filter contributed to entrapment of the particles within the filter structure and made it harder to identify the particles. In comparison, track etched polycarbonate filters have random cylindrical pores and a smooth surface which contributes to uniform sample distribution on the surface of the filter. Future work includes: testing the system using control samples to determine the efficiency and suitability of the medium, performing sample collection in various environments to establish ideal operating parameters and analyzing contaminant particles using SEM/EDS and assistant characterization techniques. Once fully developed, employing the forced air sampling method will help to prevent damage to spacecraft, avoid schedule delays, and allow for mission success.

Hernandez Melendez, Jailyn M.↗
NASA NTRSDate not supplied

Wearable Protective Technologies

We are currently creating protective garments to be worn during the duration of SPE (solar particle events). Several garment prototypes have been created to protect the body, but nothing has been created for head protection. My focus during this internship was creating headgear designs. Some of the big requirements of an effective headgear design is that the hood design needs to cover the forehead and not have any gaps between the hood and neckline, and the areal density of radiation shielding needs to be at least 1.5 g/cm2. My designs were inspired by many different brands and designers including Nike’s outerwear selection, Moncler’s Fall 20 Genius collaborations with Simone Rocha, Craig Green, and Alyx, Marine Serre F/W 20, and A-Cold-Wall S/S 19. All of these had great examples of hood and vest designs. Many sketches were created from these and many other inspirations. Pattern development began by taking several measurements of the head and neck. I drafted the hood to cover the forehead and cover the neck. After the initial draft, the pattern was modified to accommodate a center panel to contour and shape the hood further. I also created a shoulder drape based on a kimono sleeve to add extra coverage over the neckline of the garment from a basic sloper’s neckline and shoulders. Radiation shielding was a special consideration in my design work. I did extensive research on different materials and ways to incorporate them into garments and found that I was not limited to polypropylene or polyethylene. Many common textiles are hydrogen rich, such as cotton, polyester, and silk, and could be incorporated into designs as radiation shielding. From this research, I am in the process of creating a prototype that uses these materials as shielding. I will be returning for the summer and hope to put more of the ideas I have into production.

Nicole Dugan↗
NASA NTRS2022

Charging Experiments and Filtration Testing on Facemask Materials: Towards Goals of Full Performance Restoration of Used N95 Masks and Enhancement of Common-Fabric Facemasks

Different techniques have been developed for sanitizing N95 masks while retaining whatever charge remains on them. However, these sanitizing methods do not address the fact that the electrical charge, filtration efficacy, and breathability of such masks may be expected to degrade during long-term use based on mechanisms known in the literature. In this study, approaches to electrically (re)charging facemask filter materials were explored in response to the COVID-19 induced shortage of N95 masks. The effort consisted of charging experiments followed by filtration testing conducted at the coupon level during a month-long period (May 2020). The main focus of the work was to develop a recharging technique which could eventually be adapted and used as part of a broader full-performance restoration process for used N95 masks, e.g., which might employ simple washing by alcohol or soapy water as a preceding step for sanitization and declogging. Most tested coupons were therefore nonwoven meltblown fibrous polypropylene (PP) filter media extracted from decades old N95 masks. Keeping in mind commonly used cloth facemasks, limited trials were also performed with some commercially available fabrics. Charging was done at elevated temperature and was followed by cooling to freeze in the applied charges produced from corona discharges using different electrode configurations and parameter combinations, or from triboelectric rubbing. Charging was also focused on using potentially scalable equipment, e.g., Van de Graaff generators or consumer ionic hair products. Some degree of success was achieved with one of the fabrics and the PP filter media which was first purposefully discharged to have typical filtration efficiency (FE) of ~35%. Numerous attempts at corona charging discharged media resulted in filtration efficiency (FE) ≥ 80 – 85%. Some measure of charge robustness was also established via stable performance during loading testing. However, results where FE ≥ 90% were not reliably repeatable and no results met the FE ≥ 95% goal due to shortcomings of the charging process. The best three trials for PP media statistically met the FE ≥ 90% criteria, amounted to a small percentage of the trials relying on an ionic hair dryer, and are attributed to good embedding of charges via aerodynamic force. Triboelectric charging significantly enhanced the viability of one of the polyester fabrics –measured FE increased from 19% up to 46% while maintaining a reasonably low pressure drop.

N95↗
NASA NTRS2024

3D Printed Materials Characterization for Rapid Prototyping and Plant Growth

Through KSC IRTD funding in 2022, this project brought a list of 18, 3D printed filaments into formal characterization testing to provide a reference for their behaviors under relevant applications. The project format set up a series of tests to expose 3D printed specimens. A total of 1,989 individual 3D printed test specimens were sent across KSC to be scrutinized by three laboratories to fulfill a multidisciplinary assessment of each material TRL. Testing started with 18 materials. Initially, seed germination assays in the PPA, sample materials were enclosed in petri dishes with lettuce seeds on damp germination paper. No significant impacts on lettuce seed germination were observed in this testing. Next, sample coupons were printed and sent for materials testing to the KSC Analysis/Mechanical and Environmental Testing Laboratory, where they were subjected to 14- and 30-day soak periods in solutions used to provide nutrients to plants or to sanitize hardware before and after use. Following a long soak typical of a 30-day plant growout in Hoagland’s solution, 14 materials gained more than 10% of their own mass. This indicated an increased potential for leaching or providing conditions that are not food safe. Materials that exceeded 15% absorption by mass were eliminated from further testing. Based off this result, the team continued with a core list of nine filaments to fulfill Tensile, Flexural, Biofilm formation, and plant growth testing. Those materials were PLA (Raise3D), ABS (Raise3D), PETG (PolyethyleneTerephthalate Glycol) (Raise3D), ASA (Acrylonitrile Styrene Acrylate) (Raise3D), PC (Polycarbonate) (Raise3D), TPU (Thermoplastic polyurethane)-95 (Raise3D), PLA Copper (Gizmodorks), PP (Polypropylene) (Braskem), and HIPS (High Impact Polystyrene) (Gizmodorks). Testing also quantified the spectral impact of using different color 3D printed surfaces in a growth chamber. The material used for spectral testing was PLA. Printing employed a standard surface texture representative of all materials. It was shown through Tensile Testing (ASTM D638-22) that the breaking force of a 3D printed part greatly varied depending on layer orientation. This is common through all materials, and demonstrates that the strength of a 3D printed component can be maximized by layering the material normal to the primary force on the part. Four-point flexural testing (ASTM D790) provided quantities of interest, Flexural modulus, Flexural strength, Flexural stress, and strain at break within a 5% strain limit from each of nine materials. Biofilm formation testing was conducted in the Molecular and Microbiological Laboratory. Testing completed on specimens from each material showed equal formation on the surface. Additional plant growth testing was conducted in the PPA beyond the initial germination testing. The final assessment documents that three materials (PLA, ABS, and PC) have reached TRL 6 through extensive testing, and ultimate end-to-end applied use in experimental or testing conditions (flight and ground). TRL 5 materials (ASA, TPU-95, PLA Copper, PP, PETG, and HIPS) have all been successfully applied in Research and Development for crop growth applications and are ready to be applied in formal testing. TRL 4 materials Nylon910, PLA Carbon Fiber, PPA CF, PPA Glass Fiber (GF), NinjaFlex, and P-filament 721 are materials that were able to be printed and tested, but have yet to show data meeting applied requirements. TRL 3 NylonX, Flex TPE-185, and Nylon were unable to be reliably printed to fulfill testing. These results provide researchers with reference for materials to use during plant growth experimentation, and also set a standard for future characterization work applying 3D printing and materials to testing, research, and experimentation.

Gioia Massa↗
DOE OSTI2024

Synthesizing, Compounding, and Characterizing a Heat Labile Polyurethane Foam

ABSTRACT A need exists for a packaging foam material that can be converted from solid to gaseous degradation products at reasonably low energy levels or temperatures, such as 100O C. This paper will primarily discuss the approaches currently being used to synthesize and characterize such a material. These approaches include the incorporation of novel polyols such as azo containing diols, polycarbonate diols, and polypropylene carbonate polyols into polyurethane foams. Characterization methods include NMR, FTIR, TGA, finite element analysis, impact strength, and others. This project will be funded for a duration of three years. Year 1 focused on developing the proposed test methods and producing an initial rigid polyurethane foam. Year 2 focuses on refining the materials and test methods. If appropriate, design of experiment (doe) techniques will be used to optimize components, component levels, density and other variables to attain required final material properties (TGA weight loss, impact strength, etc.). Year 3 focuses on scaling up to larger engineering quantities. The application for this material is in load securement for transportation of low level radioactive waste materials within the US Department of Energy (DOE) complex. Foam in place process equipment and operators will be shielded using this novel method over current practice. Current practice can involve time consuming methods of load securement in low level radiation environments. This new technique would eliminate exposure time securing the load and greatly improve the As Low As Reasonably Attainable (ALARA) conditions. The objective is to progress to higher Technical Readiness Levels (TRL) and larger pilot scale quantities. This paper discusses methodologies and presents current results to date.

Kranjc, Mark D.↗
DOE OSTI2025

Optimizing Insulation Design for Transformers in Medium Voltage Power Conversion Systems

Medium-frequency transformers (MFTs) play a crucial role in medium-voltage (MV) solidstate transformer (SST) systems, particularly in extreme fast charging applications. Achieving partial discharge (PD)-free operation while maintaining high power density is a significant challenge due to the high electric field (E-field) stresses inherent in MV applications. This dissertation focuses on the insulation design and optimization of MFTs used in both the main power electronics circuits and auxiliary power supplies. The study begins with an overview of insulation testing methodologies, including high potential tests, basic insulation level tests, and PD tests, which are critical for evaluating MFT insulation reliability. Given the importance of PD-free operation for long-term reliability, particular emphasis is placed on understanding PD mechanisms, including void, corona, and surface discharge, and their mitigation strategies. A high voltage isolated auxiliary power supply is then introduced, utilizing a gapped transformer encapsulated in silicone gel. This design achieves PD-free insulation up to 18 kV RMS while maintaining low coupling capacitance to minimize common-mode current. The proposed solution ensures reliable operation in MV environments and offers a scalable approach for auxiliary power in cascaded SST architectures. To improve MFT insulation in main power conversion circuits, a novel structure is developed using polypropylene sheets and potting compounds to create a void-free air gap, effectively mitigating E-field intensity. A prototype transformer with this insulation structure is built and achieves PD-free operation up to 30 kV RMS. This design is experimentally validated in a resonant converter operating at 46 kW, demonstrating its feasibility for MV SST applications. Further optimization is implemented to enhance MFT performance for dual-active-bridge(DAB) converters by integrating a semiconductive shielding layer within the insulation structure. This shielding layer improves the magnetic coupling coefficient while effectively confining the E-field within high insulation materials, thereby reducing eddy current losses. The optimized MFT achieves PD-free operation at 12.6 kV RMS and is successfully tested in a DAB converter operating at 43 kW, which meets the insulation requirements for a 13.2 kV SST system. This dissertation advances MFT insulation design by introducing and experimentally validating novel approaches that improve high voltage insulation while optimizing magnetic coupling and manufacturability. The proposed insulation structures enable PD-free operation while minimizing insulation material usage and simplifying assembly, making them ideal for high power, high voltage applications.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗