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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 NTRS2019

Hypervelocity Impact Performance of 3D Printed Aluminum Panels

With the continued development of additive manufacturing methods, control over the shape of ligaments, cell regularity, and macroscopic shape can all be easily tuned. This capability allows for tailoring of component architecture and promotes potential mass savings in a space vehicle structure. Additionally, it allows one the flexibility of combining structural elements such as MMOD protection and vehicle stiffness for launch loads for an overall mass reduction. At NASA JSC this technology is being explored in many different ways with the goal being a multifunctional structural component. For this study, four different types of aluminum panels have been 3D printed for testing, three being of a body centric cubic (BCC) lattice structure core and one being kelvin cell structure core. All samples have a 5.33 cm (0.05”) nominally thick aluminum face sheet printed on the front and back side of each panel, with all core materials having a 5.08 cm (2.0”) nominal thickness (see Table 1 for test sample summary and Figures 1 – 2 for sample illustrations). These tests will evaluate the performance of 3D printed aluminum panels under hypervelocity impact (HVI) conditions. The hypervelocity impact tests are being conducted at the JSC White Sands Test Facility (WSTF) Remote Hypervelocity Test Laboratory (RHTL), located in Las Cruces, New Mexico. All tests will be conducted with a 3.4mm Al 2017-T4 sphere at 6.8 km/s impacting at 0° to surface normal (i.e., impacting with no obliquity). Each sample will be trapped between two metal frames, with gasket material residing between the sample and frame, which will be the shipping and testing configuration for all tests. There will be an Al 2017-T4 witness plate staged 5.08 cm (2.0”) from each sample to capture signature of debris, if the rear face sheet of the sample were to perforate from the HVI test event.

Davis, B. A.↗
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↗
NASA NTRS2015

Biomaterials Out of Thin Air: in Situ, On-Demand Printing of Advanced Biocomposites

Upmass is the single most significant limitation of our current space mission capability. Although biomaterials and biocomposites have mass, strength, flexibility, and self-healing properties that could significantly reduce upmass, their use is limited by the following drawbacks: Expensive, specific production. Many biomaterials can only be produced as part of significant support ecosystem; Inaccessible functional customization. The grain of wood, the porosity of bone, and so on are an integral part of the materials' desired mechanical properties, but are not deterministic when the material is naturally grown; Limited compositions. Most biomaterials (unlike metal, plastic, etc.) cannot be easily combined or modified to produce new materials. This project builds on recent advances in: Synthetic biology. Libraries of standardized genetic parts which can be used for controlled cellular material production, delivery, and binding; 3D printing. Commercial off-the-shelf components which can be used to make of a pico- to nanoliter cell deposition system; Tissue engineering. Proven cell-compatible support hydrogels and scaffolds can be modified to bind the deposited biomaterials of interest. Objectives: Feasibility and benefit analysis. Two mission contexts span the concept's scope (see below); Proof-of-concept demonstration. A simple grid of two proteins, fluorescent for easy detection, to validate the core technology concept; Proposed implementations for follow-on work. Avenues for future work on each core component (host cell, production control, material delivery, material binding, etc.); Complementary studies exploration. A survey of other emerging areas (in situ resource utilization, protein engineering, etc.) with the potential to multiply our technology's impact. Potential Impacts: This application could dramatically expand manufacturing capabilities on Earth and in space: In situ resource utilization. A far greater range of materials and products will be available from the limited palette offered by in situ resource extraction techniques; Reduced equipment and material upmass for off-Earth habitats. Ready- to-use highly specialized construction materials (radiation hardened, compressive/tensile, light or dense) from an extremely low starting mass; Structured biomaterial production. New ready-to-use macro, micro, and molecular manufacturing techniques for traditional biomaterials such as wood, bone and shell; New and novel biocomposite creation. The ability to create completely novel material composites from any base material that cells can be engineered to produce. Suggested Mission Contexts: ISS part manufacturing. A 'minimal working example' making a finished biomaterial part aboard the International Space Station; A long-term Mars habitat. 'Cradle-to-grave' use at a hypothetical Mars habitat, covering everything from tools to construction materials. Alternate Abstract: Imagine being able to print anything from tools and composite building materials to food and human tissues. Imagine being on Mars with the ability to replace any broken part, whether it's a part of your spacesuit, your habitat, or your own body. We propose a technique that would allow just that. By printing 3D arrays of cells engineered to secrete the necessary materials, the abundant in situ resources of atmosphere and regolith become organic, inorganic, or organic-inorganic composite materials. Such materials include novel, biologically derived materials not previously possible to fabricate.

habitats↗
NASA NTRS2015

Biomaterials Out of Thin Air: in Situ, On-demand Printing of Advanced Biocomposites

Upmass is the single most significant limitation of our current space mission capability. Although biomaterials and biocomposites have mass, strength, flexibility, and self-healing properties that could significantly reduce upmass, their use is limited by the following drawbacks: Expensive, specific production. Many biomaterials can only be produced as part of significant support ecosystem; Inaccessible functional customization. The grain of wood, the porosity of bone, and so on are an integral part of the materials' desired mechanical properties, but are not deterministic when the material is naturally grown; Limited compositions. Most biomaterials (unlike metal, plastic, etc.) cannot be easily combined or modified to produce new materials. This project builds on recent advances in: Synthetic biology. Libraries of standardized genetic parts which can be used for controlled cellular material production, delivery, and binding; 3D printing. Commercial off-the-shelf components which can be used to make of a pico- to nanoliter cell deposition system; Tissue engineering. Proven cell-compatible support hydrogels and scaffolds can be modified to bind the deposited biomaterials of interest. Objectives: Feasibility and benefit analysis. Two mission contexts span the concept's scope (see below); Proof-of-concept demonstration. A simple grid of two proteins, fluorescent for easy detection, to validate the core technology concept; Proposed implementations for follow-on work. Avenues for future work on each core component (host cell, production control, material delivery, material binding, etc.); Complementary studies exploration. A survey of other emerging areas (in situ resource utilization, protein engineering, etc.) with the potential to multiply our technology's impact. Potential Impacts: This application could dramatically expand manufacturing capabilities on Earth and in space: In situ resource utilization. A far greater range of materials and products will be available from the limited palette offered by in situ resource extraction techniques; Reduced equipment and material upmass for off-Earth habitats. Ready- to-use highly specialized construction materials (radiation hardened, compressive/tensile, light or dense) from an extremely low starting mass; Structured biomaterial production. New ready-to-use macro, micro, and molecular manufacturing techniques for traditional biomaterials such as wood, bone and shell; New and novel biocomposite creation. The ability to create completely novel material composites from any base material that cells can be engineered to produce. Suggested Mission Contexts: ISS part manufacturing. A 'minimal working example' making a finished biomaterial part aboard the International Space Station; A long-term Mars habitat. 'Cradle-to-grave' use at a hypothetical Mars habitat, covering everything from tools to construction materials. Alternate Abstract: Imagine being able to print anything from tools and composite building materials to food and human tissues. Imagine being on Mars with the ability to replace any broken part, whether it's a part of your spacesuit, your habitat, or your own body. We propose a technique that would allow just that. By printing 3D arrays of cells engineered to secrete the necessary materials, the abundant in situ resources of atmosphere and regolith become organic, inorganic, or organic-inorganic composite materials. Such materials include novel, biologically derived materials not previously possible to fabricate.

habitats↗
NASA NTRS2018

NASA Additive Manufacturing Initiatives for Deep Space Human Exploration

Additive Manufacturing (AM) is being infused into aerospace industries at an accelerated pace. Reasons for this rapid adoption include: (1) Innovation Capability e.g. design features such as topology optimization, integrated fluid passages, and mesh structures; (2) Rapid Development and Optimization - ability to quickly iterate the design, development, and test cycle; (3) Affordability - reductions in part counts, cost, and schedule. NASA's Marshall Space Flight Center (MSFC) has taken a leadership role in application of AM technologies for deep space human exploration, leading the Agency's In Space Manufacturing (ISM) initiative and the application of AM for a broad variety of space propulsion systems. MSFC has championed the development of ISM capabilities since our first reduced-gravity aircraft experiment flew in 1999. Partnering with Made In Space, MSFC placed the first 3D Printer on ISS in 2014 and the second generation printer, the Additive Manufacturing Facility, in 2016. The next ISS technology demonstration will be the Refabricator, a recycler/basic printer scheduled to launch in late Fall 2018. Ground-based development is progressing in common use materials, metals 3D printing, printed electronics, and the new cornerstone of ISM, the FabLab. The latest developments in each area will be described. An overview of NASA's In Space Robotic Manufacturing and Assembly (IRMA) ground-based risk reduction projects will also be presented. MSFC has aggressively incorporated AM capabilities for design and development of space propulsion components. The capabilities have been rapidly matured and extensively exercised to produce and hot-fire test the Additive Manufacturing Demonstrator Engine, an in-space class prototype engine. This experience base has been extended to support Aerojet Rocketdyne in the application of AM to the RS-25, the Space Launch System Core Stage engine, and to small propulsion systems and thrusters for small satellites and cubesats. The latest developments will be described. In responding to a request from NASA's Commercial Crew Program for a consistent methodology for evaluation of AM processes and parts, MSFC began development of a draft standard for AM space flight hardware in late 2014. The draft was broadly disseminated for comments in mid-2015, and subsequently revised into two documents, a standard and a specification for AM space flight hardware, which were formally released by MSFC in October 2017. An overview of the key elements of these documents will be presented.

Clinton, Raymond↗
NASA NTRS2012

NASA Tech Briefs, August 2012

Topics covered include: Mars Science Laboratory Drill; Ultra-Compact Motor Controller; A Reversible Thermally Driven Pump for Use in a Sub-Kelvin Magnetic Refrigerator; Shape Memory Composite Hybrid Hinge; Binding Causes of Printed Wiring Assemblies with Card-Loks; Coring Sample Acquisition Tool; Joining and Assembly of Bulk Metallic Glass Composites Through Capacitive Discharge; 670-GHz Schottky Diode-Based Subharmonic Mixer with CPW Circuits and 70-GHz IF; Self-Nulling Lock-in Detection Electronics for Capacitance Probe Electrometer; Discontinuous Mode Power Supply; Optimal Dynamic Sub-Threshold Technique for Extreme Low Power Consumption for VLSI; Hardware for Accelerating N-Modular Redundant Systems for High-Reliability Computing; Blocking Filters with Enhanced Throughput for X-Ray Microcalorimetry; High-Thermal-Conductivity Fabrics; Imidazolium-Based Polymeric Materials as Alkaline Anion-Exchange Fuel Cell Membranes; Electrospun Nanofiber Coating of Fiber Materials: A Composite Toughening Approach; Experimental Modeling of Sterilization Effects for Atmospheric Entry Heating on Microorganisms; Saliva Preservative for Diagnostic Purposes; Hands-Free Transcranial Color Doppler Probe; Aerosol and Surface Parameter Retrievals for a Multi-Angle, Multiband Spectrometer LogScope; TraceContract; AIRS Maps from Space Processing Software; POSTMAN: Point of Sail Tacking for Maritime Autonomous Navigation; Space Operations Learning Center; OVERSMART Reporting Tool for Flow Computations Over Large Grid Systems; Large Eddy Simulation (LES) of Particle-Laden Temporal Mixing Layers; Projection of Stabilized Aerial Imagery Onto Digital Elevation Maps for Geo-Rectified and Jitter-Free Viewing; Iterative Transform Phase Diversity: An Image-Based Object and Wavefront Recovery; 3D Drop Size Distribution Extrapolation Algorithm Using a Single Disdrometer; Social Networking Adapted for Distributed Scientific Collaboration; General Methodology for Designing Spacecraft Trajectories; Hemispherical Field-of-View Above-Water Surface Imager for Submarines; and Quantum-Well Infrared Photodetector (QWIP) Focal Plane Assembly.

Source record↗
NASA NTRSDate not supplied

VERNE: Revealing the Mysteries and Histories of Venus

Introduction: The three Venus missions that were recently selected for upcoming flight (VERITAS, DAVINCI+, and EnVision) will be incredibly valuable to our understanding of Venus’ history, geology, and atmosphere. However, even once completed, key gaps in our knowledge of Venus, and more generally the formation and active processes on rocky, Earth-like planets, will still persist. Remaining questions include 1) how global intrinsic magnetic fields might be maintained on rocky worlds, and how they could then go extinct, and 2) what role atmospheric sulfur chemistry plays in climates of Earth-like planets, which is an increasingly timely subject as Earth’s own atmospheric sulfur content is climbing due to human activity. These questions require in-situ observations from Venus’ cloud deck, at the altitudes at which the UV absorber exists. The Venus Environment Research and Novel Exploration (VERNE) mission will address these questions with an aerial platform that will drift around the equatorial region of the planet for 9 days. VERNE will collect data to determine the identity of the mysterious UV absorber, while also taking magnetic field measurements over the tesserae, the regions on Venus that are most likely to retain remanent crustal magnetization, in order to understand the potential role of a past intrinsically-generated global magnetic field on Venus. Mission Objectives: The two major science objectives that drive the VERNE mission are: 1) Determine the identity of the Venusian unknown ultraviolet absorber(s). First observed approximately a century ago [1], the composition of Venus’ ultraviolet (UV) absorber is one of the oldest mysteries in Venus atmospheric chemistry [2,3]. While several candidate UV absorbers (mostly sulfur species) have been proposed, no consensus has been reached on its composition and its specific interactions with the atmosphere. Determining the identity of the UV absorber will aid climate models by showing how and where incident solar energy is absorbed by the atmosphere and make progress towards understanding the chemical and energetic processes taking place above Venus’ upper cloud deck [4]. 2) Determine if Venus retains evidence of a past, internally-generated magnetic field. While Venus does not currently have an intrinsically-generated magnetic field, evidence for the existence of a past field on Venus and a timeline of its decay will fill in a more holistic picture of the evolution of Venus’ geological record and atmosphere. As the oldest geologic units on the surface, Venus’ tesserae may still have remanent crustal magnetization signatures within the rocky composition [5]. In any case, the signatures detected will provide insight into Venus’ past geological and core dynamo activity. Mission Summary: VERNE includes a 3-part flight system made up of 1) an entry system with a HEEET (Heatshield for Extreme Entry Environment Technology) aeroshell, 2) an orbiter for data relay, and 3) an in-situ balloon and gondola. After entry into Venus’ atmosphere, the balloon will be deployed within the upper cloud deck, at an altitude of 62 km, over a tesserae region. The in-situ data collection will last for the duration of 2 full circumnavigations of the planet, which will take ~9 days. Instrumentation Suite: The four instruments that comprise VERNE’s instrument payload will enable the identification of the unknown UV absorber and the detection of remanent crustal magnetization if it exists in the tesserae. The proposed instrument suite cycle during mission operations is shown in Fig. 1. The four instruments are described below: 1) Adams (ion neutral mass spectrometer) has a range of 18-257 AMU and will detect and distinguish the mixing ratios of O₂, H₂O, H₂SO₄, S, S₂, S₃, S₄, S₅, S₆, S₇, S₈, SO, SO₂, OSSO, SO₃, Cl₂, FeCl₃ and other trace sulfur and organic species. The spatial (longitudinal) and temporal (day/night) variations will be observed throughout 2 circumnavigations with a sample cadence of 12 minutes. 2) Shelley (nephelometer) will determine the size distribution of the aerosols (0.4 to 36 um) in the atmosphere. With a size resolution of <0.7 um, it can determine which mode of H2SO4 is present and characterize the large (>30 um) organic particles previously detected by the Venera and Galileo missions [6,7]. 3) Herbert (UV imager) will measure UV radiance at 283 nm (the wavelength of SO2 absorption) and 365 nm (the unknown part of the absorber). UV images will be taken concurrently with the INMS and nephelometer to correlate UV absorption with abundances of the UV absorber species. 4) Vonnegut (magnetometer) has a range of >600 nT and a precision and accuracy of 1 nT. If magnetized by a past field, the crust may have retained a magnetization of up to 3 A/m2 [5]. With a noise floor of 10 nT, the magnetometer will be able to detect RCM from an altitude of 62 km, even if the thickness of the magnetized crust is just 1 km (Fig. 2). Mission Concept Design: VERNE will be launched with a mass of 3300 kg in an intermediate-high performance class vehicle with a 4-m fairing. The 475-day mission includes 466 days for the cruise, coasting, and orbit initialization phases before entry, descent, and balloon deployment. During the 9-day science phase, the aerial platform will make 2 circumnavigations of the planet at an altitude of 62 km. The INMS and the nephelometer will acquire data for 2 hours during the daytime and nighttime during each circumnavigation, while the UV imager will be on for the duration of the daytime, and the magnetometer will be operational throughout the entirety of the science phase. Data will be stored and processed with the JPL-designed Sphinx command and data handling system. Data will be sent from the balloon to the orbiter using an S-band relay link, stored on the orbiter, and then forwarded to Earth where it will be received by the DSN. Conclusion: VERNE will fill key gaps in our understanding of the history and ongoing processes related to the geology and atmosphere of Venus and rocky worlds in general. Even with adequate flight system contingencies and expected costs below the $900M New Frontiers cost cap, VERNE is not without its risks and challenges. Further trade spaces to explore include 1) using solely battery power vs. including solar panels to increase the mission duration and 2) investigating the use of lightweight materials and 3D-printed structures to reduce the gondola mass, among others. Acknowledgments: We would like to thank the JPL Planetary Science Summer School, especially our mentors Troy Hudson, Karl Mitchell, and Leslie Lowes, as well as our Team-X study lead Al Nash and the members of Team-X. We’d additionally like to thank our review panel for asking insightful questions and providing valuable feedback. References: [1] Ross, F. E. (1928) Astrophysical J., 68, 57-92. [2] Rossow, W. B. et al. (1980) J. Geophysical Research, 85, 8107-8128. [3] Pinto, J. P. et al. (2021) Nature Communications, 12, 175. [4] Titov, D. V. et al. (2007) Cosmic Research, 21, 401. [5] O’Rourke, J. et al. (2019) Geophysical Research Lett., 46, 5768–5777. [6] Limaye, S. S. et al. (2018) Astrobiology, 18(9), 1181-1198. [7] Grinspoon, D. H. et al. (2013) Planetary and Space Sci., 41(7), 515-542. [8] Parker, R. L. (2003) J. Geophysical Research, 108, 5006. *The cost information contained in this document is of a budgetary and planning nature and is intended for informational purposes only. It does not constitute a commitment on the part of JPL and/or Caltech.

H Alpert↗