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At least 19 records
All sourcesNASA NTRSDOE OSTI
NASA NTRSDate not supplied

Large-scale Additive Manufacturing for Exploration

Additive Manufacturing (AM) is emerging as a mainstream manufacturing technology, and demand for large part manufacturing is getting stronger. Direct Metal Deposition (DMD) is a DED technology based on laser and powder metal application using a closed-loop-feedback control system. This webinar focuses on additive manufacturing of NASA’s RS-25 engine nozzle liner using DMD technology. This liner (10ft in height and 8ft in diameter) is beyond the print capability of existing 3D printing processes. To print this part, significant advancements were made to the DMD technology by deploying two process heads in the machine and expanding the machine work envelop to allow manufacturing of such large parts in a safe and efficient environment. A successful demonstration of the AM of the RS25 engine nozzle liner marks a new era in 3D printing and elevates the current 3D printing technology to a new level for affordable manufacturing of large metal parts.

Additive Manufacturing↗
NASA NTRSDate not supplied

NASA Efforts to Explore Additively Manufactured Thermal Protection Systems

Development of the thermal protection system (TPS) needed to protect external and internal surfaces during launch, ascent, cruise, and reentry, is a very specialized field with expertise developed over seven decades and has enabled successful robotic as well as human exploration. Well known examples are: 1) the ablative heatshield that protected Apollo Astronauts during reentry in 1960’s, 2) reusable TPS used on the Space Shuttle Orbiter, which is now sought after by commercial space industry, and 3) hot structures, such as Carbon-Carbon and other high temperature materials needed to operate control surfaces and sharp leading edges during hypervelocity flight. TPS function demands fail-safe design to ensure mission success. One TPS does not fit all, and each application requires a unique material along with manufacturing and integration approach. TPS mass is a key metric. A robust but inefficient TPS reduces payload mass. Mission- and domain-unique TPS development and flight certification efforts have been expensive with long lead times. As a result, there are limited TPS choices with high cost. For future commercial efforts to be successful, the ability to rapidly develop TPS, based on specific needs and at a lower cost, without compromising either mass efficiency or functionality is necessary. NASA is looking into this. Additive manufacturing (AM) techniques have shown their utility in making complex parts and, through automation, the potential to reduce cost and schedule in some applications. The promise of additive manufacturing to TPS, while exciting, is unexplored. In the past several years, NASA has made exploratory investments in internal development as well as in small business and universities through SBIR and STTR programs. In addition, NASA is bringing together the TPS as well as Additive Manufacturing communities to explore approaches to prioritize focus areas for broad benefits. The very first “Additively Manufactured Thermal Protection System Workshop,” to be held at NASA Johnson Space Center in Houston at the end of March of this year, is the culmination of a year-long effort to engage the research, development, and user communities involved in both TPS as well as additive manufacturing. The workshop participants include representatives from large and small commercial space industry, DoD, Federally Funded Research and Development Centers, University Researchers and NASA personnel. The proposed talk will highlight future TPS needs of both emerging commercial and Government interests, NASA’s development efforts in additively manufactured TPS, and the findings and recommendations from the first AM TPS Workshop.

Ethiraj Venkatapathy↗
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 NTRS2019

Additive Manufacturing for Human Space Exploration

NASA’s In Space Manufacturing Initiative (ISM): The Case for ISM - Why; ISM Path to Exploration; In Space Robotic Manufacturing and Assembly (IRMA). Additive Manufacturing (AM) Development For Liquid Rocket Engine Space Flight Hardware. MSFC (Marshall Space Flight Center) Standard and Specification For Additively Manufactured Space Flight Hardware.

Additive Manufacturing Exploration↗
NASA NTRSDate not supplied

Technology Drives Exploration: How NASA Is Embracing Additive Manufacturing

NASA has over 60 years of technology development that enabled human space and space science exploration “for the benefit of all humankind”. This presentation will start with the overview of NASA’s organization structure; the roles NASA’s leadership plays as well as 10 regional centers’ focused areas and capabilities. It will also highlight NASA’s Mission Directorates –Science, Human, Aeronautics, and Technology. With the onset of the newer and still evolving procurement business model (NASA being a buyer, instead of maker), a question remains: which is the right framework under which NASA can best integrate the capabilities of commercial, international, and other US government entities into a coherent exploration strategy? Another critical consideration is identifying which critical technologies to invest in NASA and which capabilities are better suited for commercialization as NASA as a buyer. Additive Manufacturing (AM) is certainly changing the space industry and providing new opportunities to travel to low earth orbit and explore our universe. New design opportunities –not previously possible –for new high performance metal alloys, light-weighting, managing thermal, structural, and dynamic loads are being enabled by AM. This presentation will showcase the vast portfolio of NASA’s AM activities in the last 13 years; transportation from Earth to Destination, Habitat at Destination, Lander from Station to Surface, and Science mission spacecrafts. NASA’s technical excellence is being leveraged heavily in the AM and Commercial Space community through collaborative projects, partnership agreements, tech transfer program. Examples of challenges of AM implementation as well as opportunities will be discussed.

Alison Park↗
NASA NTRS2023

Reactive Additive Manufacturing for Fourth Industrial Revolution Exploration Systems (Ramfire) Aluminum 6061-Ram2 Nozzle Testing

The NASA Marshall Space Flight Center (MSFC) has applied various forms of metallic additive manufacturing (AM) in liquid rocket engine component design, development, and testing since 2010. These AM techniques reduce hardware cost, shorten fabrication schedules, increase reliability by reducing the number of joints, and improve hardware performance by allowing unconventional design. The RAMFIRE project, funded under Space Technology Mission Directorate (STMD) Game Changing Development (GCD) Program, has furthered the use of novel AM liquid rocket nozzles in collaboration with Elementum 3D. The project advanced novel large-scale AM aluminum material technology for significant weight savings in rocket engines and launch vehicles. Previously, aluminum alloys were difficult to weld and print using additive manufacturing. Elementum 3D’s patented Aluminum 6061-RAM2 alloy allows for aluminum alloys to be printed using various AM techniques and at various scales. The alloy can be leveraged for welding wire, showing drastic improvements in aluminum weldability. The RAMFIRE project focuses on five key areas: 1) Laser Powder Directed Energy Deposition (LP-DED) AL6061-RAM2 feedstock specification and verification, 2) LP-DED process development and validation, 3) LP-DED printed AL6061-RAM2 microstructural and mechanical property characterization, 4) Hot-fire test a 7k-lbf thrust class regeneratively cooled nozzle, 5) Print large scale regeneratively cooled nozzle. Hot-fire testing demonstrates potential of advanced space technologies to NASA and potential users by providing the relevant environments to advance TRL levels to the 5/6 range.

Al6061-RAM2↗
NASA NTRSDate not supplied

STMD-GCD Reactive Additive Manufacturing for Fourth Industrial Revolution Exploration Systems (RAMFIRE)

Elementum 3D, in partnership with NASA-MSFC under an ACO, seeks to help further increase launch performance and reduce launch and mission cost by advancing novel additively manufactured (AM) aluminum materials for large-scale complex rocket components and launch vehicle structures. The proposed outcome of this ACO is to advance large-scale directed energy deposition (DED) of highstrength aluminum alloys through process development, characterization, and testing.

RAMFIRE↗
NASA NTRS2016

The Crucial Role of Additive Manufacturing at NASA

At NASA, the first steps of the Journey to Mars are well underway with the development of NASA's next generation launch system and investments in research and technologies that should increase the affordability, capability, and safety of exploration activities. Additive Manufacturing presents a disruptive opportunity for NASA to design and manufacture hardware with new materials at dramatically reduced cost and schedule. Opportunities to incorporate additive manufacturing align very well with NASA missions and with most NASA programs related to space, science, and aeronautics. The Agency also relies on many partnerships with other government agencies, industry and academia.

Vickers, John↗
NASA NTRS2017

NASA's Additive Manufacturing Development Materials Science to Technology Infusion - Connecting the Digital Dots

At NASA, the first steps of the Journey to Mars are well underway with the development of NASA's next generation launch system and investments in research and technologies that should increase the affordability, capability, and safety of exploration activities. Additive Manufacturing presents a disruptive opportunity for NASA to design and manufacture hardware with new materials at dramatically reduced cost and schedule. Opportunities to incorporate additive manufacturing align very well with NASA missions and with most NASA programs related to space, science, and aeronautics. The Agency also relies on many partnerships with other government agencies, industry and academia.

Vickers, John↗
NASA NTRSDate not supplied

Developing Radiation Protection Garments with Additive Manufacturing

The RadWorks Wearable Technology team is dedicated to developing protective garments to ameliorate the effects of radiation caused by Solar Particle Events (SPEs). This work requires that we remain open to new avenues for processing hydrogen-rich materials that may be useful in the development of these protective garments. The purpose of this research was to identify new ways of processing polyolefin polymers (polypropylene, more specifically) with additive manufacturing techniques. First, we conducted a literature review to identify known problems with processing polypropylene using additive manufacturing. Then, we looked toward finding ways to manage these difficulties within the additive manufacturing process. The primary goal was to develop techniques for processing polypropylene in a way that would generate a product amenable to inclusion in a worn garment (e.g., flexible, strong, and with ample radiation protection). In the end, we were able to generate designs which addressed polypropylene’s high coefficient of thermal expansion and lack of material adhesion, while meeting the requirements set forth by the use-case for wearable technology. This research offers novel avenues for processing one of the most common plastics in the world, which could contribute to the development of protective garments, as well as new avenues to explore for additive manufacturing in low-gravity environments.

Additive Manufacturing, 3D Printing, Polypropylene↗