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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 19 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

3D scanning and 3D printing AlSi10Mg single crystal mounts for neutron scattering

Here, we present methods to quantify sample shapes and generate sample mounts as motivated by the needs of neutron scattering experiments. The 3D sample scanning was performed using photogrammetry and laser scanning, and a comparison is made between the two techniques. The aluminum alloy AlSi10Mg is shown to have favorable properties for many types of mounts used in neutron scattering. Parts were first prototyped with 3D plastic printers, and then, 3D AlSi10Mg prints were made. The final additively manufactured part holds the sample with more points of contact than is possible with traditional manufacturing. The goodness of fit between the mount and sample was measured by x-ray tomography.

47 OTHER INSTRUMENTATION↗
NASA NTRSDate not supplied

3D Scanning Laboratory

The 3D Scanning Lab uses a number of technologies to capture 3D surface data. Those technologies are structured light scanning, discrete point measurement photogrammetry and Light Detecting and Ranging(LIDAR). Structured light is a non-contact optical technique used to capture as built surface geometries quickly and accurately. LIDAR is a laser scanning technique used to capture 3D surfaces. And photogrammetry uses a certified DSLR camera to measure discrete registered and non-registered points in 3D space. MSFC’s 3D Scanning Team uses 3D scanning to provide hardware inspections, reverse engineered CAD models, manufacturing/process development and digital assemblies. The inspection process compares the captured data to CAD, providing a color plot detailing the deviations of the scan data to the CAD model. Dimensional measurements and GD&T can also be interrogated. Inspection can provide scan-to-scan data comparisons which is ideal for assessing tested hardware, e.g. comparing data captured before and after hardware testing. Reverse engineering is used to develop CAD models from scan data. This is useful for heritage hardware studies, developing building or structural models and inputs for simulation studies and design efforts. The lab uses the 3D surface scan data to drive manufacturing/machining processes, termed match machining. This technique has been used to modify nozzles, injectors, additive manufactured parts, composite barrel sections, etc. Parts of an assembly can be scanned and assembled in a virtual environment providing an accurate 3D representation of the assembled hardware in its as-scanned state. This can provide detailed information of internal components that would otherwise not be accessible.

Advanced Manufacturing↗
DOE OSTI2015

SU-E-T-676: Reproducibility and Consistency of Two SunNuclear 3D Scanning Tanks

Purpose: To determine if two Sun Nuclear 3D Scanning (SNC 3DS) tanks collect reproducible and consistent data and test the precision of the SNC Dosimetry auto-setup. Methods: Percent depth doses (PDDs) and profiles were collected on two SNC 3DS tanks with a Varian TrueBeam linear accelerator. SNC Dosimetry auto-setup application was used with CC13 ionization chambers. After auto-setup, collimator light field was checked manually against the position of the chamber. Comparing measured data for repeated measurements with tank 1 allowed evaluation of SNC-3DS auto-setup and tank reproducibility. Comparing measured data between tanks 1 and 2 allowed evaluation of consistency between tanks. Results: Preliminary results showed reproducibility of depth of maximum dose (Dmax) of 0.38mm for a 10cmx10cm field and 0.67mm for 30cmx30cm on a single tank. PDD values at 5cm, 10cm, and 20cm depths were reproducible within 0.26%. Consistency of Dmax between tanks was 0.17mm for a 10cmx10cm field and 0.44mm for 30cmx30cm. PDD values at 5cm, 10cm, and 20cmwere consistent within 0.06%. Profiles showed reproducibility in field width within 0.4mm for a 10cmx10cm field and 0.7mm for a 30cmx30cm field. Profiles showed consistency in field width within 0.2mm for 10cmx10cm and 30cmx30cm field sizes. Penumbra width was reproducible and consistent to under 0.5mm except for 30cmx30cm field size at 30cm depth where the reproducibility was 2.2mm and the consistency was 2.6mm. Conclusion: In conclusion, the SNC 3DS tank shows good reproducibility in measured data. Since the tank to tank variation in measured data is within the uncertainty of repeated single tank measurements the tanks also perform consistently.

07 ISOTOPE AND RADIATION SOURCES↗
DOE OSTI2015

Documentation and Instructions for Running Two Python Scripts that Aid in Setting up 3D Measurements using the Polytec 3D Scanning Laser Doppler Vibrometer

Sandia National Laboratories has recently purchased a Polytec 3D Scanning Laser Doppler Vibrometer for vibration measurement. This device has proven to be a very nice tool for making vibration measurements, and has a number of advantages over traditional sensors such as accelerometers. The non-contact nature of the laser vibrometer means there is no mass loading due to measuring the response. Additionally, the laser scanning heads can position the laser spot much more quickly and accurately than placing an accelerometer or performing a roving hammer impact. The disadvantage of the system is that a significant amount of time must be invested to align the lasers with each other and the part so that the laser spots can be accurately positioned. The Polytec software includes a number of nice tools to aid in this procedure; however, certain portions are still tedious. Luckily, the Polytec software is readily extensible by programming macros for the system, so tedious portions of the procedure can be made easier by automating the process. The Polytec Software includes a WinWrap (similar to Visual Basic) editor and interface to run macros written in that programming language. The author, however, is much more proficient in Python, and the latter also has a much larger set of libraries that can be used to create very complex macros, while taking advantage of Python’s inherent readability and maintainability.

47 OTHER INSTRUMENTATION↗
DOE OSTI2025

Aerodynamic Characterization of 3D Scanned Wind Turbine Blades Using Experimental and Computational Methods

This study presents an aerodynamic characterization of 3D scanned wind turbine blades using both experimental and computational methods. The research was conducted by Gulf Wind Technology and Sandia National Laboratories. The primary objective was to investigate the aerodynamic impacts of leading-edge manufacturing defects on wind turbine blades. The study utilized the Stratasys NEO 800 3D Printer for high-precision manufacturing and the GWT Accelerator Wind Tunnel for experimental testing. Computational simulations were performed using COMSOL Multiphysics to model the wind tunnel and analyze flow characteristics and OpenFOAM to study the aerodynamic impacts of leading-edge defects. OpenFAST was used to estimate how these defects can lead to revenue losses for wind farm operators as high as 6%. The results demonstrated significant aerodynamic performance variations due to defects, with detailed analysis provided through wind tunnel and CFD data. The findings contribute to the understanding of defect impacts on wind turbine blade performance and offer insights for future design improvements.

17 WIND ENERGY↗
DOE OSTI2016

Sci-Sat AM: Radiation Dosimetry and Practical Therapy Solutions - 07: A mould room in a box – 3D scanning and printing technology in the radiotherapy clinic

Purpose: We describe the process by which our centre is currently implementing 3D printing and scanning technology for treatment accessory fabrication. This technology can increase efficiency and accuracy of accessory design, production and placement during daily use. Methods: A low-cost 3D printer and 3D optical scanner have been purchased and are being commissioned for clinical use. Commissioning includes assessing: the accuracy of the 3D scanner through comparison with high resolution CT images; the dosimetric characteristics of polylactic acid (PLA) for electron beams; the clinical utility of the technology, and; methods for quality assurance. Results: The agreement between meshes generated using the 3D scanner and CT data was within 2 millimeters for an anthropomorphic head phantom. In terms of electron beam attenuation, 1 centimetre of printed PLA was found equivalent to 1.17 cm of water. In proof-of-concept tests, several types of treatment accessories have been prototyped to date that will benefit from this technology. These include electron and photon bolus for areas with complex surface contours including the ear for electron treatments, the extremities for photon treatments and lead shielding for orthovoltage treatments. Imaging with CT and x-ray showed minimal defects, which will have no significant clinical impact. Geometric fidelity and fit to volunteers and patients was found to be excellent. Conclusions: 3D Printing and scanning can increase efficiency in the clinic for treatments requiring custom accessories. Customized boluses and shielding had excellent fit and reduced uncertainty in positioning.

60 APPLIED LIFE SCIENCES↗
NASA NTRS2024

3D Scanning System to Assess Gravity-Dependent Body Shape Changes

The human body shows unique physiological and morphological changes when exposed to different gravity conditions, including muscle atrophy, fluid shift, spinal elongation, and body posture adjustments. Such changes need to be incorporated for human-system integration in the vehicle habitat, garment, and spacesuit designs, as inaccurate body measurements can result in suboptimal crew protection that can potentially decrease injury tolerance. However, the traditional linear measurements, such as stature, segment lengths or circumferences measured using a caliper or tape measure, often show limited consistency and are unable to capture the nonlinear characteristics of the human body. While 3D body scanning can provide significant advantages over linear measurements, the technologies have not been fully developed or customized for in-flight scanning. For ground laboratory use, several different scanner types are commercially available. However, in-flight scanning requires additional technical considerations, such as minimal scan time, simplified calibration, and sufficient capture volume. This work aims to develop a prototype 3-D body scanning system that is customized for in-flight use to scan crewmembers, with the configuration and performance optimized for detecting known gravity-dependent body shape and posture changes. A hardware system will be custom built using a network of commercial off-the-shelf 3D sensors. The sensor parameters and settings will be optimized to detect the targeted body shape changes, specifically using body manikins of which the shape and size are iteratively permuted to simulate the known changes by fluid shift and spinal elongation. The capture volume will be also matched for a range of body sizes from a 1st percentile female to 99th percentile male. Unintentional body motions or floating in microgravity will be also simulated and incorporated. A data acquisition software will be developed for efficient in-flight operations with minimal overhead and easy-to-use user interface. A simplified calibration procedure will be designed for robust scanning against frequent vibration or unexpected sensor position shifts. The system will be tested in the ground laboratory for accuracy and reliability against a reference scanning system. New anthropometry measurements will be also identified to sensitively capture the gravity dependent body shape changes, in addition to the traditional anthropometry measurements. A novel landmark-based technique will be tested for consistent anthropometry measurements across posture variations. If successfully developed and deployed, the new system is expected to provide previously unavailable body shape and size data from different gravitational environments, including 0-g, 1/6-g, and 1-g. Such data can improve suit fit, habitat design, exercise efficacy quantification and sizing of orthostatic intolerance garments.

K H Kim↗
NASA NTRS2024

3D Scanning System to Assess Gravity-Dependent Body Shape Changes

The human body shows unique physiological and morphological changes when exposed to different gravity conditions, including muscle atrophy, fluid shift, spinal elongation, and body posture adjustments. Such changes need to be incorporated for human-system integration in the vehicle habitat, garment, and spacesuit designs, as inaccurate body measurements can result in suboptimal crew protection that can potentially decrease injury tolerance. However, the traditional linear measurements, such as stature, segment lengths or circumferences measured using a caliper or tape measure, often show limited consistency and are unable to capture the nonlinear characteristics of the human body. While 3D body scanning can provide significant advantages over linear measurements, the technologies have not been fully developed or customized for in-flight scanning. For ground laboratory use, several different scanner types are commercially available. However, in-flight scanning requires additional technical considerations, such as minimal scan time, simplified calibration, and sufficient capture volume. This work aims to develop a prototype 3-D body scanning system that is customized for in-flight use to scan crewmembers, with the configuration and performance optimized for detecting known gravity-dependent body shape and posture changes. A hardware system will be custom built using a network of commercial off-the-shelf 3D sensors. The sensor parameters and settings will be optimized to detect the targeted body shape changes, specifically using body manikins of which the shape and size are iteratively permuted to simulate the known changes by fluid shift and spinal elongation. The capture volume will be also matched for a range of body sizes from a 1st percentile female to 99th percentile male. Unintentional body motions or floating in microgravity will be also simulated and incorporated. A data acquisition software will be developed for efficient in-flight operations with minimal overhead and easy-to-use user interface. A simplified calibration procedure will be designed for robust scanning against frequent vibration or unexpected sensor position shifts. The system will be tested in the ground laboratory for accuracy and reliability against a reference scanning system. New anthropometry measurements will be also identified to sensitively capture the gravity dependent body shape changes, in addition to the traditional anthropometry measurements. A novel landmark-based technique will be tested for consistent anthropometry measurements across posture variations. If successfully developed and deployed, the new system is expected to provide previously unavailable body shape and size data from different gravitational environments, including 0-g, 1/6-g, and 1-g. Such data can improve suit fit, habitat design, exercise efficacy quantification and sizing of orthostatic intolerance garments.

K H Kim↗
DOE OSTI2022

REGULATORY TESTING AND 3D SCANNING METHODOLOGY OF THE DPP-1 TYPE SHIPPING CONTAINER FOR NCT AND HAC TESTS

The safe transportation of radioactive material using appropriately designed and certified transportation packages is important to protect the public and environment. In the United States of America all transportation of radioactive material is regulated by the Department of Transportation (DOT) along with input by the Nuclear Regulatory Commission (NRC). All packages that contain radioactive material requires that it be transported and regulated by the requirements set by the DOT Class 7 hazardous material transportation. Federal regulations place strict administrative controls on the transport of radioactive materials. The two main goals for transporting radioactive materials are 1. Safety should be the primarily focused on the package because it is the first line of defense. 2. Package integrity should be directly related to the degree of the hazard of the radioactive material contents. The two-part goal ensures that the right package is used. Type B packages are designed to transport radioactive materials with the highest level of radioactivity. Examples of material transported in Type B packagings include spent nuclear fuel, high-level radioactive waste, and high concentrations of other radioactive materials. The purpose of this test protocol is to determine the effects of drop and thermal testing on package performance in a Type B shipping package (DPP-1). Required physical tests for the DPP-1 package include free drop, crush, puncture, penetration, compression, vibration, water spray, water immersion, and thermal. The preparation, regulatory testing, and post-test evaluation of a Type B shipping package tested to the 10 CFR 71.71 and 10 CFR 71.73 requirements will be presented. Six packages were tested and the responses when subjected to the HAC sequence of free drop, puncture, and thermal tests according to 10 CFR 71.73(c)(1), (c)(2), (c)(3) and (c)(4) were measured. The Free Drop, Crush and Puncture tests were performed at the NTRC in Knoxville, TN, and the Thermal tests were performed Southwest Research Institute in San Antonio, TX. The test units were subjected to a pre-operational leak testing before the NCT and HAC tests and a post-operational leak test and a helium leak test once regulatory testing was complete. Finally, all test units were scanned with a handheld blue light scanner to capture a 3D CAD geometry of the test units in the deformed shape. The handheld scanner provided the most effective and reliable way to acquire accurate 3D measurements of the test unit. The scanned geometry was sectioned in areas with deformation and the cross-section profile was measured to determine accurate and repeatable results of the deformed shape of the test units.

Martinez, Oscar↗
NASA NTRSDate not supplied

3D Scanning System to Assess Gravity-Dependent Body Shape Changes

The human body shows unique morphological changes when exposed to different gravity conditions, including muscle atrophy, fluid shift, and spinal elongation. Such changes need to be incorporated for human-system integration in the vehicle habitat, garment, and spacesuit designs, as inaccurate body measurements can result in suboptimal crew protection that can potentially decrease injury tolerance. However, measurement tools have not been available for accurate assessments of body shape changes. This work aimed to develop a prototype 3-D body scanning system with the configuration and performance optimized for in-flight crewmember body scanning. A scan hardware system was developed using Intel RealSense commercial off-the-shelf 3D sensors. The sensor parameters were iteratively optimized and tested to obtain the performance level needed for body scanning. A scan booth structure was fabricated, with the overall size 4 x 4 x 8 feet. The specific number of sensors and mounting positions were determined by iterative simulations, which indicated that 16 cameras can capture 94% and 96% of body surface area from the 1st percentile female and 99th percentile male crew population subject. The mounted sensors were linked through a mix of USB-C and USB-3 cables and operated for data acquisition from a Linux laptop computer. A software prototype was developed using Python and Tkinter graphical user interface toolkit. A calibration procedure was also built using a panel of QR codes. A computer vision tool detected and decoded the unique ID and pattern locations of the QR codes. The calibration information determined the position and orientation of the 3D sensors with respect to each other. The scanner performance was assessed using a set of 3D printed custom manikins. The manikin size and shape were derived from the previous ISS study, which measured the crewmembers’ anthropometry changes across the different flight phases. The average anthropometric measurements at the pre-flight and flight day 15 were sampled and projected onto the 1st percentile female and 99th percentile male body shapes. Another pair of manikins were also 3D printed to simulate the neutral body posture, estimated from ISS microgravity environments. A preliminary analysis assessed the performance of the newly developed scanner against the reference scanner, which has been used at the NASA JSC for crew and test subject anthropometry. Although the new scanner data showed several artifacts and missing geometries in the occluded body areas such as armpits and crotch, overall shape matched with the reference scan. When the manikin surface coordinates were compared, a root mean square error of 1.3 cm was observed from the manikin torso segment. Linear measurements including the stature, knee height and circumference measurements at the chest and calf showed differences from the reference scan measurements, ranging between 0.3 and 0.9 cm. Overall, this work demonstrated a development framework for an in-flight scanner with design and operation optimized for crewmember body scanning. Further improvement can potentially provide previously unavailable anthropometric data from different gravitational environments, including 0-g, 1/6-g, and 1-g. Such data can improve suit fit, habitat design, exercise efficacy quantification and sizing of orthostatic intolerance garments.

K H Kim↗