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AIAA Ascend 2021 Conference On Demand Manufacturing of Electronics Panel Abstract

1. Session Proposal o Session Title NASA’s In Space Manufacturing and the On Demand Manufacturing of Electronics o Session Topic Primary -- Space Logistics, Autonomy, and Robotics; Secondary – Transformative Research and Technologies o Session Format: Panel Discussion. o Requested Session Duration: 60 minutes o Short Session Description: The goal of NASA’s On Demand Manufacturing of Electronics project is to develop and demonstrate the feasibility of a low-gravity, on-demand manufacturing system for flexible hybrid electronic devices on the International Space Station. This panel will feature several key collaborators and team members from the commercial sector, academia, and internal to NASA, each of which are contributing an unique and vital role to the design and implementation of this new technology system. o Extended Session Description (Please describe in detail the activity proposed, including how you intend to use the requested session duration. This session description will be provided to the reviewers for consideration and will not be displayed in the online agenda.): The session will be moderated by Curtis Hill, the Project Lead for the On Demand Manufacturing of Electronics (ODME), and he will start by giving a brief introduction to the ODME project which is working to produce a demo system for the manufacturing of electronic devices on the International Space Station. Panelists consisting of collaborators and team members to the ODME project will then give a brief (~5 min) introduction highlighting their contributions to the project, followed by time for Q&A from the audience. The panel will consist of: 1. Kenneth Church, nScrypt. nScrypt is a leader in multi-material printing with a modular system that incorporates a direct write thick film print head, a polymer fused filament fabrication print head, a laser sintering attachment, a drill head attachment for milling, and a pick and place. The system can print a layer and scan for accuracy of prints. The combination of multiple print heads and scanning allows for the on-demand production of intricate electronic components. 2. Andy Kurk, TechShot, Inc. Techshot, Inc. has collaborated extensively with NASA on the in space manufacturing of both printed electronics and fused metal materials. They are currently working to develop and integrate a test system for printed electronics, and a flight demonstration on the International Space Station is anticipated in 2024. 3. Ed Hendricks, NextFlex. NextFlex has the goal of advancing the manufacture of flexible hybrid electronics in the U.S. They are working with ODME on the development of AstroSense, an additively manufactured, wireless, flexible, and wearable health sensor. 4. Dr. Pradeep Lall, Auburn University. Professor Lall is the MacFarlane Endowed Distinguished Professor in the Department of Mechanical Engineering with a Courtesy Joint Appointment in the Department of Electrical and Computer Engineering and a Courtesy Joint Appointment in the Department of Finance. He is collaborating with NASA’s ODME project to develop multilayer printable devices and to develop techniques to test the quality of a printed electronic device. 5. Dr. Wei Gao, California Institute of Technology. Professor Gao is an Assistant Professor of Medical Engineering. His group is developing fully printed, flexible, and wearable biosensors for crew health monitoring in collaboration with NASA’s ODME project. In addition, they are working on using sweat to power biofuel cells for wearable, self-powered electronic devices. 6. Beth Paquette, NASA Goddard. The ODME branch at NASA Goddard is spearheading a sounding rocket flight demo to prove the capability of a printed electronic device with multiple sensors. In addition, they focus on thin film and flexible energy storage evaluations. o Session Goal(s)/Outcome(s): Please list the learning objectives and/or tangible outcomes (technical paper or other publication). The goal of this session is to highlight the internal and collaborative efforts of NASA’s On Demand Manufacturing of Electronics project to develop a system for printing electronics that will be tested on the International Space Station in 2024. In addition, the session with facilitate discussion with the community on the state of the art of printable electronics, current challenges, and new avenues for collaboration.

Jennifer McInnis Jones↗

Space Studies Board Annual Report, 2009

The year 2009 was one of transition for the nation, for NASA, and for the Space Studies Board (SSB). The nation pulled back from 2008's economic precipice, but did not return to the path of economic growth that it had been on. The United States inaugurated a new president who set out to build his administration. By mid-year President Obama had announced the appointment of Charlie Bolden as NASA administrator, and Lori Garver as deputy administrator. The president and Charlie Bolden jointly appointed an independent commission, the now well-known Augustine Commission, to provide guidance on the future of NASA's human spaceflight program. Many had known for quite a while that NASA's human spaceflight program faced a profound change at the time of the retirement of the space shuttle. This year was also a year of transition for the SSB. In 2009, Marcia Smith stepped down as staff director for both SSB and ASEB, and Dick Rowberg had a very good turn at the plate as a pinch-hitter. We are deeply indebted to both of them. We are pleased that, after a successful run as study director for Astro2010, Michael Moloney is now director of SSB and ASEB. The profound work begun in 2009 on the decadal surveys will only see the light of day later as they are released and the scientific work begins. The SSB will have much to report for 2010.

National Aeronautics and Space Administration(NASA↗

Human Dimensions of Energy Systems Workshop - September 6-7, 2022: Findings and Next Steps

Advanced energy technologies and informed policies are necessary but not sufficient to accelerate the energy transition at the speed required to meet our shared climate and energy resilience goals. To fully understand and implement integrated energy systems, we need to be able to model and analyze the complete system-of-systems, including the behavior of people interacting with and being impacted by energy systems. The purpose of this workshop is: Understand how human behavior and decisions affect the performance of energy systems with a focus on resilience and human well-being; Identify opportunities to improve energy system design to explicitly consider human behavior and well-being; Enhance our capability to model and predict human actions. Develop the ability to stress test these integrated systems; Identify or develop requirements and tools for more robust system designs that can be used for human-in-the-loop exercises and training; Identify opportunities for joint research, joint appointments, and collaboration; and Guide internal investments and strategic hires.

analyze↗

Flaw Tolerance in Lap Shear Brazed Joints

Vacuum brazing is a viable process to achieve strong permanent and hermetic joints in space. As in any joining process, brazed Joints have various imperfections and defects. It is important to understand the impact that flaws have on the load carrying capacity and performance of the brazed joints. This study focuses on the behavior of lap shear joints due to their engineering importance in brazed aerospace structures. In Part 1 an average shear strength capabilitY and failure modes of the single lap joints are explored. Specimens comprised of 0.090 inch thick 347 stainless steel sheet brazed with pure silver are tested in accordance with the AWS C3.2 standard. Comparison of the measured loads and average shear stresses at failure with the Finite Element Analysis (FEA) of the same specimens as a function of the overlap lengths shows excellent correlation between the experimental and calculated values for the defect-free lap joints. In Part 2, various flaws will be introduced in the test specimens to simulate lack of braze coverage in the lap joints. Mechanical testing and FEA will be performed on these joints to verify if behavior of ductile ]appoints containing flaws is similar to the joints with the reduced braze area. Finally, in Part 3, the results obtained in Part 1 and 2 will be applied to the brazed assembly to evaluate a load carrying capability of the structural lap joint containing defects.

Flom, Yury↗

Flight 20 (STS-45) polysulfide gas path investigation

This report documents the results of the investigation into causes of gas paths on the 20A and 20B case-to-nozzle joints on STS-42. The investigation was conducted by the Investigation Board appointed by the senior vice president and general manager of Space Operations, Mr. R. E. Lindstrom, on 7 Feb. 1992. The probability of gas path occurrence in the nozzle-to-case-joint polysulfide had been identified during joint redesign. However, actual flight gas path incidence has been limited to RSRM-11 and the 20A and 20B segments. The blow-by condition on the 20A segment was a first time occurrence which was a special concern. The investigation covered all technical aspects associated with the gas path and blow-by conditions: materials and processing history, design requirements and as-built compliance to the design, thermal and structural analyses, computer modeling, and laboratory experimentation with the materials involved. The investigation was coordinated with Mr. Ken Jones at NASA Marshall in bi-weekly teleconferences. The Board also supported Dr. James C. Blair's independent NASA investigation team by providing copies of collected data, conducting requested analyses, and supporting several all-day teleconferences to provide understanding and resolve issues. The Dr. Blair support requirement was successfully concluded on 4 Mar. 1992.

Bjorkman, Rey C.↗

Operation Dominic

A very tall (6’5”) Austin McGuire endured duty aboard the cramped confines of a submarine during World War II. After receiving a doctorate in physics from the University Rochester, he came to Los Alamos in 1954, later participating in the Koa shot of Operation Hardtack I. In 1962, he was appointed Deputy Commander of the Los Alamos task unit of Joint Task Force 8 (8.1.1) and sent to Christmas Island for Operation Dominic.

45 MILITARY TECHNOLOGY, WEAPONRY, AND NATIONAL DEF↗

Ulysses - An ESA/NASA cooperative programme

Cooperation between ESA and NASA is discussed, noting that the Memorandum of Understanding lays the framework for this relationship, defining the responsibilities of ESA and NASA and providing for appointment of leadership and managers for the project. Members of NASA's Jet Propulsion Laboratory and ESA's ESTEC staff have been appointed to leadership positions within the project and ultimate control of the project rests with the Joint Working Group consisting of two project managers and two project scientists, equally representing both organizations. Coordination of time scales and overall mission design is discussed, including launch cooperation, public relations, and funding of scientific investigations such as Ulysses. Practical difficulties of managing an international project are discussed such as differing documentation requirements and communication techniques, and assurance of equality on projects.

Meeks, W.↗

A Core Program in JIAFS

This paper presents appendices listing and summarizing funding of, and participants in the project, for a final report on A Core Program in JIAFS (Joint Institute for Advancement of Flight Sciences). The objectives of the program were to conduct high-risk innovative research, administer and direct the on-going programs, and appoint additional Graduate Research Scholar Assistants depending on availability of applicants and funds.

Whitesides, John L.↗

Core Program in the Joint Institute for Advancement of Flight Sciences

Following the precedent started several years ago, each of the graduating MS and DSc candidates in JIAFS present a seminar which is advertised throughout the area. Following the formal seminar the attendees are excused and the review committee examines the student as in a standard thesis defense. This allows the students to gain experience in presenting their research and disseminating the Institute's research results to a wider audience. A list of seminars are given in Appendix B. Some 172 excellent applications for the Graduate Research Scholar Assistantships were received during this period. Forty-nine new GRSA were appointed by Professor Whitesides to JTAFS under the various research grants and contracts.

Source record↗

Evolution of Trajectory Design Requirement of NASA's Planned Europa Clipper Mission

Europa is one of the most scientifically intriguing targets in planetary science due to its potential suitability for extant life. As such, NASA has funded the California Institute of Technology Jet Propulsion Laboratory and the Johns Hopkins University Applied Physics Laboratory to jointly develop the planned Europa Clipper mission—a multiple Europa flyby mission architecture aimed to thoroughly investigate the habitability of Europa and provide reconnaissance data to determine a landing site that maximizes the probability of both a safe landing and high scientific value for a potential future Europa lander. The trajectory design—a major enabling component for this Europa Clipper mission concept—was developed to maximize science from a set of eight model payload instruments determined by a NASA-appointed Europa Science Definition Team (SDT) between 2011-2015. On May 26, 2015, NASA officially selected 10 instruments from 6 different U.S. research facilities and universities. With the selection of instruments have come the development of new science measurement requirements, as well as a rich set of requirements stemming from project policies, planetary protection, and the evolved capability and characteristics of the flight system and mission operations system. This paper will focus on the evolution of requirements levied on the trajectory design, discuss strategies and solutions to the multidimensional optimization problem of designing high fidelity end-to-end trajectories that maximize Europa science while mitigating mission risk, complexity and cost, and last, verification of candidate trajectories to meet the requirements on the trajectory design.

Buffington, Brent↗

Vehicle Assembly Building Fire Mishap Investigation Report. Volume I of V

On January 13, 2005, at approximately 1355, smoke was noticed on the 4th floor of D Tower in the Vehicle Assembly Building (VAB). Subsequently, a 911 call was made, a fire alarm pull station was activated, and the VAB was evacuated. The source of the smoke was determined to be a fire on the Low Bay M/N section roof near the Launch Control Center (LCC) Crossover. Due to the high visibility of the mishap, the KSC Center Director appointed a Mishap Investigation Board. Damage to government property was limited to the roof and a small number of ceiling tiles that were damaged by the fire fighters during the response. At the time of the mishap, there were hazardous commodities in the VAB including Solid Rocket Motors (SRMs) with open grain due to Solid Rocket Booster (SRB) igniter inspections. The Board agrees with the SGS Fire Services' theory that large amounts of smoke concentrated in the VAB D Tower and moved downward into the cable tunnel. The Board determined the proximate cause of this incident to be torching. HRI was installing a torch applied roof membrane which resulted in the ignition of combustible materials under the membrane near a wooden roof expansion joint. The torch applied roofing method is a universally accepted safe industry practice when applied to non-combustible surfaces. The combination of an open flame torch and combustible materiaLs presents an increased level of risk even with skilled applicators. The addition of high winds to this combination results in a risk the Board thinks can not be adequately mitigated. An appropriate risk assessment and analysis must be performed on the proposed roofing method to be used on high visibility facilities which represent unique national assets even when using common industry practices for repair and modification. The Board identified three root causes which contributed to or created the proximate cause and, if eliminated or modified, would have prevented the mishap: 1. Combustible materials in existing roof system 2. Wind speed and direction 3. Inadequate fire watch technique. Two contributing factors were identified which may have contributed to the occurrence but, if eliminated or modified, would not have prevented the occurrence: 1. HRI rushed to dry in and seal the roof on January 13 because heavy rain was predicted for the next day 2. No guidance on torching in windy conditions A total of 17 significant observations were noted during this investigation, which could lead to another mishap, or increase the severity of a mishap, but were not contributing factors in this mishap.

Kight, Ira↗

Clementine: An inexpensive mission to the Moon and Geographos

The Clementine Mission, a joint project of the Strategic Defense Initiative Organization (SDIO) and NASA, has been planned primarily to test and demonstrate a suite of lightweight sensors and other lightweight spacecraft components under extended exposure to the space environment. Although the primary objective of the mission is to space-qualify sensors for Department of Defense applications, it was recognized in 1990 that such a mission might also be designed to acquire scientific observations of the Moon and of Apollo asteroid (1620) Geographos. This possibility was explored jointly by SDIO and NASA, including representatives from NASA's Discovery Program Science Working Group, in early 1991. Besides the direct return of scientific information, one of the benefits envisioned from a joint venture was the development of lightweight components for possible future use in NASA's Discovery-class spacecraft. In Jan. 1992, SDIO informed NASA of its intent to fly a 'Deep Space Program Science Experiment,' now popularly called Clementine; NASA then formed an advisory science working group to assist in the early development of the mission. The Clementine spacecraft is being assembled at the Naval Research Laboratory, which is also in charge of the overall mission design and mission operations. Support for mission design is being provided by GSFC and by JPL. NASA's Deep Space Network will be utilized in tracking and communicating with the spacecraft. Following a recommendation of the COMPLEX committee of the Space Science Board, NASA will issue an NRA and appoint a formal science team in early 1993. Clementine is a 3-axis stabilized, 200 kg (dry weight) spacecraft that will be launched on a refurbished Titan-2G. One of the goals has been to build two spacecraft, including the sensors, for $100M. Total time elapsed from the decision to proceed to the launch will be two years.

Shoemaker, Eugene M.↗

High Pressure Vent Line Mishap: Investigation Summary

During testing on the E-1 Test Stand, the High Pressure (HP) Liquid Hydrogen (LH) vent line was displaced off its supports, damaging the expansion joints (EJ), piping, and pipe supports of the line. The damage to the vent line is believed to have occurred during Cell 3 testing on Thursday, September 21, during the first test of the day. The fuel systems being used for Cell 3 testing are connected to the LP and HP LH Vent systems and are being used in Liquid Natural Gas (LNG) service. The Cell 3 interface bleed valve that discharges to the HP LH Vent system was inadvertently left at 100% open during the chill-in process for longer than the typical amount of time. Since this valve is usually at a lower set point or intermittently closed during the chill-in process, more than the typical amount of LNG flowed into the vent line as pre-test procedures continued as normal. The open bleed valve was noticed before test preparations were completed and prior to refilling of the HP LH Tank before test. The test sequence was started, run, and shutdown normally. Video of the flare stack showed an atypical discharge of liquid at the flare stack exit. Pressure downstream of the Cell 3 interface bleed valve (a valve connected to the southernmost part of the vent system) spiked to a higher-than-normal level. No evidence of damage was captured at the time of the event. The system was used in a typical fashion after the event and for 4 subsequent tests on Thursday and Friday, before the damage was observed. A drive-by inspection of the flare stack was performed on Friday (September 22nd) morning before sunrise and before test activities began, but no damage of the vent line was observed at that time. No abnormal system behavior was observed during testing on Friday. The damage was discovered and reported to NASA Test Operations on Monday, initiating the Incident Response Team. The Mishap appointment letter was issued September 27th to formally initiate the Mishap Investigation.

LNG↗