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NASA NTRS2016

3D Printing in Zero G Technology Demonstration Mission: Summary of On-Orbit Operations, Material Testing, and Future Work

Human space exploration to date has been limited to low Earth orbit and the moon. The International Space Station (ISS), an orbiting laboratory 200 miles above the earth, provides a unique and incredible opportunity for researchers to prove out the technologies that will enable humans to safely live and work in space for longer periods of time and venture farther into the solar system. The ability to manufacture parts in-space rather than launch them from earth represents a fundamental shift in the current risk and logistics paradigm for human spaceflight. In particularly, additive manufacturing (or 3D printing) techniques can potentially be deployed in the space environment to enhance crew safety (by providing an on-demand part replacement capability) and decrease launch mass by reducing the number of spare components that must be launched for missions where cargo resupply is not a near-term option. In September 2014, NASA launched the 3D Printing in Zero G technology demonstration mission to the ISS to explore the potential of additive manufacturing for in-space applications and demonstrate the capability to manufacture parts and tools on-orbit. The printer for this mission was designed and operated by the company Made In Space under a NASA SBIR (Small Business Innovation Research) phase III contract. The overarching objectives of the 3D print mission were to use ISS as a testbed to further maturation of enhancing technologies needed for long duration human exploration missions, introduce new materials and methods to fabricate structure in space, enable cost-effective manufacturing for structures and mechanisms made in low-unit production, and enable physical components to be manufactured in space on long duration missions if necessary. The 3D print unit for fused deposition modeling (FDM) of acrylonitrile butadiene styrene (ABS) was integrated into the ISS Microgravity Science Glovebox (MSG) in November 2014 and phase I printing operations took place from November through December of that year. Phase I flight operations yielded 14 unique parts (21 total specimens) that could be directly compared against ground-based prints of identical geometry manufactured using the printer prior to its launch to ISS. The 3DP unit functioned safely and produced specimens necessary to advance the understanding of the critical design and operational parameters for the FDM process as affected by the microgravity environment. From the standpoint of operations, 3DP demonstrated the ability to remove parts from the build-tray on-orbit, teleoperate the printer from the ground, perform critical maintenance functions within defined human factors limits, produce a functional tool that could be evaluated for form/fit/function, and uplink a new part file from the ground and produce it on the printer. The flight parts arrived at NASA Marshall Space Flight Center in Huntsville, Alabama in April 2015, where they underwent months of testing in the materials and processes laboratory. Ground and flight prints completed the following phases of testing: photographic/visual inspection, mass and density evaluation, structured light scanning, XRay and CT, mechanical testing, optical microscopy, scanning electron microscopy, and chemical analysis. This presentation will discuss the results of this testing as well as phase II operations for the printer, which took place in June and July of 2016. Lessons learned from the tech demo and their impacts on the design and development of the second generation 3D printer for ISS, the Additive Manufacturing Facility (AMF) by Made In Space will also be presented. In addition, progress in other elements of NASA's In Space Manufacturing (ISM) initiative such as the on-demand ISM utilization catalog, in-space Recycler ISS Technology Demonstration development, launch packaging recycling, in-space printable electronics, development of higher strength polymeric materials for 3D printing and Additive Construction by Mobile Emplacement (ACME) will also be addressed.

Prater, Tracie↗

NASA NTRS2017

NASA's In-Space Manufacturing Project: A Roadmap for a Multimaterial Fabrication Laboratory in Space

Human space exploration to date has been limited to low Earth orbit and the moon. The International Space Station (ISS) provides a unique opportunity for NASA to partner with private industry for development and demonstration of the technologies needed to support exploration initiatives. One challenge that is critical to sustainable and safer exploration is the ability to manufacture and recycle materials in space. This paper provides an overview of NASA's in-space manufacturing (ISM) project, its past and current activities (2014-2017), and how technologies under development will ultimately culminate in a multimaterial fabrication laboratory ("ISM FabLab") to be deployed on the International Space Station in the early 2020s. ISM is a critical capability for the long endurance missions NASA seeks to undertake in the coming decades. An unanticipated failure that can be adapted for in low earth orbit, through a resupply launch or a return to earth, may instead result in a loss of mission while in transit to Mars. To have a suite of functional ISM capabilities that are compatible with NASA's exploration timeline, ISM must be equipped with the resources necessary to develop these technologies and deploy them for testing prior to the scheduled de-orbit of ISS in 2024. The presentation provides a broad overview of ISM projects activities culminating with the Fabrication Laboratory for ISS. In 2017, the in-space manufacturing project issued a broad agency announcement for this capability. Requirements of the Fabrication Laboratory as stated in the solicitation will be discussed. The FabLab will move NASA and private industry significantly closer to changing historical paradigms for human spaceflight where all materials used in space are launched from earth. While the current ISM FabLab will be tested on ISS, future systems are eventually intended for use in a deep space habitat or transit vehicle. The work of commercial companies funded under NASA's Small Business Innovative Research Program (SBIR) is also discussed, as these activities, from development of recyclable packaging for ISS to additive manufacturing capabilities for metals and electronics, could also potentially be infused into future exploration capabilities. Key data from ISM projects to date will also be summarized.

Prater, Tracie↗

NASA NTRS2018

NASA's In-Space Manufacturing Project: Toward a Multimaterial Fabrication Laboratory for the International Space Station

uman space exploration to date has been limited to low Earth orbit and the moon. The International Space Station (ISS) provides a unique opportunity for NASA to partner with private industry for development and demonstration of the technologies needed to support exploration initiatives. One challenge that is critical to sustainable and safer exploration is the ability to manufacture and recycle materials in space. This paper provides an overview of NASA's in-space manufacturing (ISM) project, its past and current activities, and how technologies under development will ultimately culminate in a multimaterial fabrication laboratory ("ISM FabLab") to be deployed on the International Space Station in the early 2020s. ISM is a critical capability for the long endurance missions NASA seeks to undertake in the coming decades. An unanticipated failure that can be adapted for in low earth orbit, through a resupply launch or a return to earth, may instead result in a loss of mission while in transit to Mars. To have a suite of functional ISM capabilities that are compatible with NASA's exploration timeline, ISM must be equipped with the resources necessary to develop these technologies and deploy them for testing prior to the scheduled de-orbit of ISS in 2024. The paper provides a broad overview of ISM projects activities culminating with the Fabrication Laboratory for ISS. The FabLab will move NASA and private industry significantly closer to changing historical paradigms for human spaceflight where all materials used in space are launched from earth. While the current ISM FabLab will be tested on ISS, future systems are eventually intended for use in a deep space habitat or transit vehicle. The work of commercial companies funded under NASA's Small Business Innovative Research Program (SBIR) is also discussed, as these activities, from development of recyclable packaging for ISS to additive manufacturing capabilities for metals and electronics, could also potentially be infused into FabLab exploration capabilities as well.

Prater, Tracie↗

NASA NTRS2008

Production of Methane and Water from Crew Plastic Waste

Recycling is a technology that will be key to creating a self sustaining lunar outpost. The plastics used for food packaging provide a source of material that could be recycled to produce water and methane. The recycling of these plastics will require some additional resources that will affect the initial estimate of starting materials that will have to be transported from earth, mainly oxygen, energy and mass. These requirements will vary depending on the recycling conditions. The degredation products of these plastics will vary under different atmospheric conditions. An estimate of the the production rate of methane and water using typical ISRU processes along with the plastic recycling will be presented.

Captain, Janine↗

NASA NTRS1972

Thermal testing techniques for space shuttle thermal protection system panels

An experimental system was developed for evaluation of the effects of aerodynamic heating and cooling, vacuum, and pressure loading on candidate insulation packages proposed for use on the space shuttle. The system includes a number of design features which facilitate rapid recycle times. This is necessary to efficiently conduct extensive thermal cycling tests on these insulation packages to determine their reuse capabilities. The heart of the system is a 26-inch graphite element radiant heater. A susceptor plate functions as a uniform-temperature intermediate radiating surface. The susceptor also forms the lid of an inert atmosphere enclosure which separates the heater from the oxidizing test atmosphere. In some tests the plate properly simulates the heating from an actual flight heat-shield panel. Although other materials were used at lower required test temperatures, 2500 F was routinely achieved using a coated columbium susceptor plate.

Cox, B. G.↗

NASA NTRS1992

Liquid air cycle engines

Given here is a definition of Liquid Air Cycle Engines (LACE) and existing relevant technologies. Heat exchanger design and fabrication techniques, the handling of liquid hydrogen to achieve the greatest heat sink capabilities, and air decontamination to prevent heat exchanger fouling are discussed. It was concluded that technology needs to be extended in the areas of design and fabrication of heat exchangers to improve reliability along with weight and volume reductions. Catalysts need to be improved so that conversion can be achieved with lower quantities and lower volumes. Packaging studies need to be investigated both analytically and experimentally. Recycling with slush hydrogen needs further evaluation with experimental testing.

Rosevear, Jerry↗

NASA NTRS2016

Biodigester Feasibility and Design for Space & Earth

Anaerobic digestion converts organic waste into methane gas and fertilizer effluent. The ICA-developed prototype system is designed for planetary surface operation. It uses passive hydrostatic control for reliability, and is modular and redundant. The serpentine configuration accommodates tight geometric constraints similar to the ISS ECLSS rack architectures. Its shallow, low-tilt design enables (variable) lower-g convection than standard Earth (1 g) digesters. This technology will reuse and recycle materials including human waste, excess food, as well as packaging (if biodegradable bags are used).

Shutts, Stacy↗

NASA NTRS2014

Investigation of Bio-Regenerative Life Support and Trash-to-Gas Experiment on a 4-Month Mars Simulation Mission

Future crewed missions to other planets or deep space locations will require regenerative Life Support Systems (LSS) as well as recycling processes for mission waste. Constant resupply of many commodity materials will not be a sustainable option for deep space missions, nor will stowing trash on board a vehicle or at a lunar or Martian outpost. The habitable volume will decline as the volume of waste increases. A complete regenerative environmentally controlled life support system (ECLSS) on an extra-terrestrial outpost will likely include physico-chemical and biological technologies, such as bioreactors and greenhouse modules. Physico-chemical LSS do not enable food production and bio-regenerative LSS are not stable enough to be used alone in space. Mission waste that cannot be recycled into the bio-regenerative ECLSS can include excess food, food packaging, clothing, tape, urine and fecal waste. This waste will be sent to a system for converting the trash into high value products. Two crew members on a 120 day Mars analog simulation, in collaboration with Kennedy Space Centers (KSC) Trash to Gas (TtG) project investigated a semi-closed loop system that treated non-edible biomass and other logistical waste for volume reduction and conversion into useful commodities. The purpose of this study is to show how plant growth affects the amount of resources required by the habitat and how spent plant material can be recycled. Real-time data was sent to the reactor at KSC in Florida for replicating the analog mission waste for laboratory operation. This paper discusses the 120 day mission plant growth activity, logistical and plant waste management, power and water consumption effects of the plant and logistical waste, and potential energy conversion techniques using KSCs TtG technology.

Trash-to-Gas↗

NASA NTRS2014

Investigation of Bio-Regenerative Life Support and Trash-To-Gas Experiment on a 4 Month Mars Simulation Mission

Future crewed missions to other planets or deep space locations will require regenerative Life Support Systems (LSS) as well as recycling processes for mission waste. Constant resupply of many commodity materials will not be a sustainable option for deep space missions, nor will storing trash on board a vehicle or at a lunar or Martian outpost. The habitable volume will decline as the volume of waste increases. A complete regenerative environmentally controlled life support system (ECLSS) on an extra-terrestrial outpost will likely include physico-chemical and biological technologies, such as bioreactors and greenhouse modules. Physico-chemical LSS do not enable food production and bio-regenerative LSS are not stable enough to be used alone in space. Mission waste that cannot be recycled into the bio-regenerative ECLSS can include excess food, food packaging, clothing, tape, urine and fecal waste. This waste will be sent to a system for converting the trash into the high value products. Two crew members on a 120 day Mars analog simulation, in collaboration with Kennedy Space Centers (KSC) Trash to Gas (TtG) project investigated a semi-closed loop system that treated non-edible biomass and other logistical waste for volume reduction and conversion into useful commodities. The purposes of this study are to show the how plant growth affects the amount of resources required by the habitat and how spent plant material can be recycled. Real-time data was sent to the reactor at KSC in Florida for replicating the analog mission waste for laboratory operation. This paper discusses the 120 day mission plant growth activity, logistical and plant waste management, power and water consumption effects of the plant and logistical waste, and potential energy conversion techniques using KSCs TtG reactor technology.

trash to gas↗

NASA NTRS1998

Development of Paper Products from Dried Sweetpotato Stems and Peanut Shells

One of the goals of NASA's Advanced Life Support Program (ALS) for sustaining human life in space is to achieve a closed system in plant production and usage. That all inedible plant parts should be recycled or used in some way. A Tuskegee University team researching sweetpotato and peanut for ALS has developed paper products from dried sweet-potato stems and peanut shells. In this study, the sweet-potato stems and peanut shells were soaked separately in water for 48 hours. After 48 hours, researchers manually separated the pulp and the unusable parts. To form the paper, 160 g of pulp and water mixture was poured through a 15.1 cm (diameter) filtration funnel and the pulp was trapped on 15 cm (diameter) filter paper. The filter paper and pulp were dried in an air oven, and the filter paper was removed, An examination under a scanning electron microscope showed that the sweet-potato paper was composed of "fibers", whereas the peanut shell paper was composed of "blocks". Results of physical testing showed that the sweet-potato stem paper was stronger than the peanut shell paper. It is anticipated that there may be other uses of these products such as writing paper, bags and packaging material. Because of its biodegradability, it can be incorporated into the resource recycling system at the end of its use.

R McConnell↗

NASA NTRS1990

Industrial plastics waste: Identification and segregation

Throwaway plastic products, mainly packaging, are inundating our landfills and incinerators. Most are ethenic thermoplastics, which can be recycled as new products or fossil-fuels. Lab experiments are described, involving destructive and non-destructive tests for identifying and using plastics. The burn-test, with simple apparatus and familiar samples, is recommended as quick, cheap and effective.

Widener, Edward L.↗

NASA NTRS2010

Creating Methane from Plastics: Recycling at a Lunar Outpost

The high cost of re-supply from Earth demands resources to be utilized to the fullest extent for exploration missions. Recycling is a key technology that maximizes the available resources by converting waste products into useful commodities. One example of this is to convert crew member waste such as plastic packaging, food scraps, and human waste, into fuel. The ability to refuel on the lunar surface would reduce the vehicle mass during launch and provide excess payload capability. The goal of this project is to determine the feasibility of recycling waste into methane on the lunar outpost by performing engineering assessments and lab demonstrations of the technology. The first goal of the project was to determine how recycling could influence lunar exploration. Table I shows an estimation of the typical dried waste stream generated each day for a crew of four. Packaging waste accounts for nearly 86% of the dry waste stream and is a significant source of carbon on the lunar surface. This is important because methane (CH4) can be used as fuel and no other source of carbon is available on the lunar surface. With the initial assessment indicating there is sufficient resources in the waste stream to provide refueling capabilities, the project was designed to examine the conversion of plastics into methane.

Captain, Janine↗

NASA NTRS1992

Human life support during interplanetary travel and domicile. VI - Generic modular flow schematic for hybrid physical/chemical-biological life support systems

An extension is proposed for the NASA Space Exploration Initiative's Generic Modular Flow Schematics for physical/chemical life support systems which involves the addition of biological processes. The new system architecture includes plant, microbial, and animal habitat, as well as the human habitat subsystem. Major Feedstock Production and Food Preparation and Packaging components have also been incorporated. Inedible plant, aquaculture, microbial, and animal solids are processed for recycling.

Ganapathi, Gani B.↗

NASA NTRSDate not supplied

The Trash Compaction Processing System (TCPS) Technology Demonstration and Risk Reduction Updates FY23-FY24

The Next STEP Phase BTrash Compaction Processing System (TCPS) is being developed for a technology demonstration on the International Space Station(ISS) to process common spacecraft consumables trash such as food packaging and clothing to reduce trash storage volume, recover water, safen(e.g. reduce biological activity), and shape the trash for storage, jettison, reuse (e.g.,radiation shielding) and/or recycling. Sierra Space is developing the flight demonstration hardware and National Aeronautics and Space Administration(NASA) continues to conduct risk reduction activities to exploreoperational scenarios, setting the stage for successful on-orbit tests. After the flight demonstration on ISS, the TCPS becomes available to be infused into NASA short-and long-term missions.This paper will discuss the rationale for the updated requirement definitions outlined in the 2023 International Conference on Environmental System TCPS paper and the ongoing risk reduction activities. In addition, drawing from lessons learned in the development of the TCPS, a discussion of other compression technologies will be introduced for various mission types.

Trash Compaction Processing System↗

NASA NTRSDate not supplied

The Trash Compaction Processing System (TCPS) Technology Demonstration and Risk Reduction Updates FY23-FY24 Presentation

Trash Compaction Processing System↗

NASA NTRS2010

Creating Methane from Plastic: Recycling at a Lunar Outpost

The high cost of re-supply from Earth demands resources to be utilized to the fullest extent for exploration missions. The ability to refuel on the lunar surface would reduce the vehicle mass during launch and provide excess payload capability. Recycling is a key technology that maximizes the available resources by converting waste products into useful commodities. One example of this is to convert crew member waste such as plastic packaging, food scraps, and human waste into fuel. This process thermally degrades plastic in the presence of oxygen producing CO2 and CO. The CO2 and CO are then reacted with hydrogen over catalyst (Sabatier reaction) producing methane. An end-to-end laboratory-scale system has been designed and built to produce methane from plastic, in this case polyethylene. This first generation system yields 12-16% CH4 by weight of plastic used.

Santiago-Maldonado, Edgardo↗

NASA NTRS1994

Recycling of volatiles at subduction zones: Noble gas evidence from the Tabar-Lihir-Tanga-Feni arc of papua New Guinea

Convergent margin processes play an important but poorly understood role in the distribution of terrestrial volatile species. For example, subduction processes filter volatiles from the subducting package, thereby restricting their return to the mantle. In addition, once extracted from the downgoing slab, volatiles become an essential component in the petrogenesis of island arc magmas. The noble gases, with their systematic variation in physical properties and diversity of radiogenic isotopes, should carry a uniquely valuable record of these processes. However, thus far studies of noble gases in arc volcanics have achieved only limited success in this regard. Subduction-related lavas and geothermal fluids carry (3)He/(4)He ratios equal to or slightly lower than those found in the depleted upper mantle source of mid-ocean ridge basalts. Apparently slab-derived helium (which should have (3)He/(4)He much less than MORB) is extensively diluted by MORB-like helium from the mantle wedge, making it difficult to use helium as a tracer of convergent margin processes. Interpretation of the heavier noble gases (Ne-Ar-Kr-Xe) in arc lavas has also proven difficult, because the lavas carry low noble gas concentrations and hence are subject to pervasive atmospheric contamination. The low noble gas concentrations may be a consequence of degassing in the high level magma chambers characteristic of arc stratovolcanos. We have recently initiated a project to better constrain the behavior of volatiles in subduction zones through geochemical studies of the tectonically unusual volcanoes of the Tabar-Lihir-Tanga-Feni (TLTF) arc in the Bismarck Archipelago, Papua New Guinea.

Farley, Kenneth↗

NASA NTRS1991

Space life support engineering program

This report covers the first six months of work performed under the NASA University Grant awarded to Iowa State University to perform research on two topics relating to the development of closed-loop long-term life support systems. A comprehensive study to develop software to simulate the dynamic operation of water reclamation systems in long-term closed-loop life support systems is being carried out as part of an overall program for the design of systems for a Mars voyage. This project is being done in parallel with a similar effort in the Department of Chemistry to develop durable accurate low-cost sensors for monitoring of trace chemical and biological species in recycled water supplies. Aspen-Plus software is being used on a group of high-performance workstations to develop the steady state descriptions for a number of existing technologies. Following completion, a dynamic simulation package will be developed for determining the response of such systems to changes in the metabolic needs of the crew and to upsets in system hardware performance.

Seagrave, Richard C.↗