Reversibly Assembled Microparticles for Sustained Applications on the Moon and Mars
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Additive Manufacturing↗
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Reversibly Assembled Microparticles for Sustained Applications on the Moon and Mars
A sustained presence in any extra-terrestrial environment will require the capability to generate materials, goods, and ultimately vehicles, construction supplies and habitats to be tenable. As an example, NASA, in collaboration with Made In Space, Inc., recently reported the results of extensive research toward enabling3D printing in space. The extensive characterization and comparison of 3D printed articles suggested that, overall, articles generated in the International Space Station microgravity environment were comparable to those generated on Earth. The benefit of in-space manufacturing can be increased through utilization of recyclable materials. A recent analysis of a hypothetical 1,100 day round trip mission to Mars determined that significant mass savings and increase in mission probability of success could be achieved through in-space manufacturing with recyclable materials. NASA’s project ESPUR (Enabling Sustained Presence Using Recyclables), through support from NASA Langley’s Innovative Research and Development Fund, is investigating novel, polymer-coated, epoxy microparticle systems as an enabling technology to realize in-space manufacturing using recyclable feedstocks. Building from previously reported results, further progress toward synthesis of the polymer coating containing click chemical functionalities will be described here. Finite elemental analysis (FEA) has been utilized, in light of scale-free/small world considerations in an effort to identify compositions most likely to yield robust macroscopic geometries. Initial results will be described here. Finally, potential mass savings and life cycle of this recyclable materials technology will be discussed.
Click Chemistry↗
SpRoUTS (Space Robot Universal Truss System): Reversible Robotic Assembly of Deployable Truss Structures of Reconfigurable Length
Automatic deployment of structures has been a focus of much academic and industrial work on infrastructure applications and robotics in general. This paper presents a robotic truss assembler designed for space applications - the Space Robot Universal Truss System (SpRoUTS) - that reversibly assembles a truss from a feedstock of hinged andflat-packed components, by folding the sides of each component up and locking onto the assembled structure. We describe the design and implementation of the robot and show that the assembled truss compares favorably with prior truss deployment systems.
Deployable↗
Backward assembly planning with DFA analysis
An assembly planning system that operates based on a recursive decomposition of assembly into subassemblies, and analyzes assembly cost in terms of stability, directionality, and manipulability to guide the generation of preferred assembly plans is presented. The planning in this system incorporates the special processes, such as cleaning, testing, labeling, etc. that must occur during the assembly, and handles nonreversible as well as reversible assembly tasks through backward assembly planning. In order to increase the planning efficiency, the system avoids the analysis of decompositions that do not correspond to feasible assembly tasks. This is achieved by grouping and merging those parts that can not be decomposable at the current stage of backward assembly planning due to the requirement of special processes and the constraint of interconnection feasibility. The invention includes methods of evaluating assembly cost in terms of the number of fixtures (or holding devices) and reorientations required for assembly, through the analysis of stability, directionality, and manipulability. All these factors are used in defining cost and heuristic functions for an AO* search for an optimal plan.
Lee, Sukhan↗
Backward assembly planning with DFA analysis
An assembly planning system that operates based on a recursive decomposition of assembly into subassemblies is presented. The planning system analyzes assembly cost in terms of stability, directionality, and manipulability to guide the generation of preferred assembly plans. The planning in this system incorporates the special processes, such as cleaning, testing, labeling, etc., that must occur during the assembly. Additionally, the planning handles nonreversible, as well as reversible, assembly tasks through backward assembly planning. In order to decrease the planning efficiency, the system avoids the analysis of decompositions that do not correspond to feasible assembly tasks. This is achieved by grouping and merging those parts that can not be decomposable at the current stage of backward assembly planning due to the requirement of special processes and the constraint of interconnection feasibility. The invention includes methods of evaluating assembly cost in terms of the number of fixtures (or holding devices) and reorientations required for assembly, through the analysis of stability, directionality, and manipulability. All these factors are used in defining cost and heuristic functions for an AO* search for an optimal plan.
Lee, Sukhan↗
Design of Multifunctional Hierarchical Space Structures
We describe a system for the design of space structures with tunable structural properties based on the discrete assembly of modular lattice elements. These lattice elements can be constructed into larger beam-like elements, which can then be assembled into large scale truss structures. These discrete lattice elements are reversibly assembled with mechanical fasteners, which allows them to be arbitrarily reconfigured into various application-specific designs. In order to assess the validity of this approach, we design two space structures with similar geometry but widely different structural requirements: an aerobrake, driven by strength requirements, and a precision segmented reflector, driven by stiffness and accuracy requirements. We will show agreement between simplified numerical models based on hierarchical assembly and analytical solutions. We will also present an assessment of the error budget resulting from the assembly of discrete structures. Lastly, we will address launch vehicle packing efficiency issues for transporting these structures to lower earth orbit.
Aeronautics↗
TPSAS-NF1676L-31522-DND
Currently, there are limitations in launch capability regarding requisite payload volume and mass for long duration extra-terrestrial missions. In-space additive manufacturing may provide a solution to this challenge and is applicable for articles ranging from large system and subsystem architectures to small consumables and replacement articles. For small articles, additive manufacturing is becoming more feasible through advances in instrumentation and novel manufacturing strategies capable of generating complex shapes. Many approaches, however, utilize feedstock materials that, once consumed, must be replenished before additional architectures can be generated. Thus, although promising, a major challenge with additive manufacturing is the required starting materials to support on-demand article generation. This presentation describes research toward reversibly assembling materials that can revert to the starting material state for subsequent fabrication. Polyimides were synthesized with thermally reversible Diels-Alder reaction functionalities, furan or maleimide moieties. These materials were characterized utilizing typical spectroscopic, thermal, and mechanical techniques. Amine hardener-enriched epoxy microparticles were synthesized for use as a mechanically robust substrate. Integration of these technologies into a single system and application toward generation of secondary structures on a launch vehicle as a means of in-situ resource utilization will be described.
Christopher J. Wohl↗
Meso-Scale Digital Materials: Modular, Reconfigurable, Lattice-Based Structures
We present a modular, reconfigurable system for building large structures. This system uses discrete lattice elements, called digital materials, to reversibly assemble ultralight structures that are 99.7% air and yet maintain sufficient specific stiffness for a variety of structural applications and loading scenarios. Design, manufacturing, and characterization of modular building blocks are described, including struts, nodes, joints, and build strategies. Simple case studies are shown using the same building blocks in three different scenarios: a bridge, a boat, and a shelter. Field implementation and demonstration is supplemented by experimental data and numerical simulation. A simplified approach for analyzing these structures is presented which shows good agreement with experimental results.
Reconfigurable↗
ESPUR Spring 2020 Internship Exit Presentation
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Self-assembly↗
MMIC-I: A Robotic Platform for Assembly Integration and Internal Locomotion through Mechanical Meta-Material Structures
In-space assembly is crucial to creating large-scale space structures and enabling long term space missions. Natural limitations in the size of transportation vehicles and ISRU production facilities necessitate an additive strategy with the size of the typical structural unit being essentially fixed and inversely proportional to the final assembly size. In prior robotic and space assembly examples, reversible mechanical integration of structural modules is typically achieved with actuated alignment and fastening mechanisms onboard every structural module. Additive assembly or manufacturing planning approaches often feature a “build front” that receives new materials or parts and progresses gradually across the target geometry. The system we describe here places much of the alignment and fastener actuation systems onboard a mobile robot that can operate at a build front while companion robots (Scaling Omni-directional Lattice Locomoting Explorer, SOLLE) provide part or material transportation. The design and evaluation of this Mobile Meta-Material Interior Co-Integrator (MMIC-I), an inchworm-style locomoting robotic assembler, is described here with an emphasis on ease of assembly and a low number of unique parts for a simple design. It is designed to assist in alignment of cuboctahedron structural unit cells with captive fasteners, defining the build front in operation. Adjacent structural unit cells are locked together with specified axial and rotational actuation of the fasteners. Hardware prototypes show that the robot is able to successfully locomote to any indexed location within a lattice structure and bolt together each set of fasteners on any interface.
Robotics↗
Functional and Multifunctional Polymers: Materials for Smart Structures
The ultimate goal of the research in smart structures and smart materials is the development of a new generation of products/devices which will perform better than products/devices built from passive materials. There are a few examples of multilayer polymer systems which function as smart structures, e.g. a synthetic muscle which is a multilayer assembly of a poly(ethylene) layer, a gold layer, and a poly(pyrrole) layer immersed in a liquid electrolyte. Oxidation and reductions of the active pyrrole layer causes the assembly to reversibly deflect and mimic biological muscles. The drawback of such a setup is slow response times and the use of a liquid electrolyte. We have developed multifunctional polymers which will eliminate the use of a liquid electrolyte, and also because the functionalities of the polymers are within a few hundred angstroms, an improved response time to changes in the external field should be possible. Such multifunctional polymers may be classified as the futuristic 'smart materials.' These materials are composed of a number of different functionalities which work in a synergistic fashion to function as a device. The device performs on the application of an external field and such multifunctional polymers may be scientifically labeled as 'field responsive polymers.' Our group has undertaken a systematic approach to develop functional and multifunctional polymers capable of functioning as field responsive polymers. Our approach utilizes multicomponent polymer systems (block copolymers and graft copolymers), the strategy involves the preparation of block or graft copolymers where the functionalities are limited to different phases in a microphase separated system. Depending on the weight (or volume) fractions of each of the components, different microstructures are possible. And, because of the intimate contact between the functional components, an increase in the synergism between the functionalities may be observed. In this presentation, three examples of multifunctional polymers developed in our labs will be reported. The first class of multifunctional polymers are the microphase separated mixed (ionic and electronic) conducting or MIEC block copolymers. The second class being developed in our labs are the biocompatible conductive materials and the conductive fluids. The final class may be considered microwave active smart polymers.
Arnold, S.↗
Recyclable Polymers With Reversible Click-Chemistry for in Space Manufacturing Applications
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Sustainable Presence↗
Sample Return Container Opening Process Concept for Potential Mars Sample Return
Proposed Mars Sample Return (MSR) missions would require a pristine and secure opening method to ensure sample Contamination Control and backward Planetary Protection. In order to reach the samples, a series of five containers would need to be opened inside of a Mars Returned Sample Handling (MRSH) facility. The process would include opening the Containment Assurance Module (CAM) aboard the Earth Entry Vehicle (EEV), the Secondary Containment Vessel (SCV), Primary Containment Vessel (PCV), and the Orbiting Sample (OS) container, and finally removing and opening the Returned Sample Tube Assemblies (RSTA). Some of these containers can be opened by reversing the mechanical assembly process while others would require destructive means. Several containers are still in a conceptual design phase while others are en route to Mars aboard the M2020 rover. In order to inform the design of the containers that are still in the conceptual stages, a study was performed at each level of the containment assembly. The studies were used to determine the least destructive and most robust methods to disassemble and open the containers while minimizing risk to the samples or the personnel. In addition to the envisioned disassembly and breaching method, contingency plans were made for completing the disassembly if damage to the vehicle and containment system occurred.
Liu, Yang↗
Twin Target Thrust Reverser Module
A nozzle assembly for a dual gas turbine engine propulsion system includes a housing mountable proximate to a first bypass passage of a first gas turbine engine and a second bypass passage of a second gas turbine engine, first and second upper doors, and first and second lower doors. Each of the first and second upper doors and the first and second lower doors are pivotally mounted to the housing for movement between a stowed position and a deployed position in which airflow through the first and second bypass passages is redirected relative to respective centerline axes of the first and second gas turbine engines.
Suciu, Gabriel L.↗
Self-Calibrating Pressure Transducer
A self-calibrating pressure transducer is disclosed. The device uses an embedded zirconia membrane which pumps a determined quantity of oxygen into the device. The associated pressure can be determined, and thus, the transducer pressure readings can be calibrated. The zirconia membrane obtains oxygen .from the surrounding environment when possible. Otherwise, an oxygen reservoir or other source is utilized. In another embodiment, a reversible fuel cell assembly is used to pump oxygen and hydrogen into the system. Since a known amount of gas is pumped across the cell, the pressure produced can be determined, and thus, the device can be calibrated. An isolation valve system is used to allow the device to be calibrated in situ. Calibration is optionally automated so that calibration can be continuously monitored. The device is preferably a fully integrated MEMS device. Since the device can be calibrated without removing it from the process, reductions in costs and down time are realized.
Lueck, Dale E.↗
Discrete Assemblers Utilizing Conventional Motion Systems
An alternative to additive manufacturing is disclosed, introducing an end-to-end workflow in which discrete building blocks are reversibly joined to produce assemblies called digital materials. Described is the design of the bulk-material building blocks and the devices that are assembled from them. Detailed is the design and implementation of an automated assembler, which takes advantage of the digital material structure to avoid positioning errors within a large tolerance. To generate assembly sequences, a novel CAD/CAM workflow is described for designing, simulating, and assembling digital materials. The structures assembled using this process have been evaluated, showing that the joints perform well under varying conditions and that the assembled structures are functionally precise.
Langford, William Kai↗
Reversible Bonding of Aromatic Thermosetting Copolyesters for In‐Space Assembly
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Jacob L. Meyer↗
Alignment Pins for Assembling and Disassembling Structures
Simple, easy-to-use, highly effective tooling has been devised for maintaining alignment of bolt holes in mating structures during assembly and disassembly of the structures. The tooling was originally used during removal of a body flap from the space shuttle Atlantis, in which misalignments during removal of the last few bolts could cause the bolts to bind in their holes. By suitably modifying the dimensions of the tooling components, the basic design of the tooling can readily be adapted to other structures that must be maintained in alignment. The tooling includes tapered, internally threaded alignment pins designed to fit in the bolt holes in one of the mating structures, plus a draw bolt and a cup that are used to install or remove each alignment pin. In preparation for disassembly of two mating structures, external supports are provided to prevent unintended movement of the structures. During disassembly of the structures, as each bolt that joins the structures is removed, an alignment pin is installed in its place. Once all the bolts have been removed and replaced with pins, the pins maintain alignment as the structures are gently pushed or pulled apart on the supports. In assembling the two structures, one reverses the procedure described above: pins are installed in the bolt holes, the structures are pulled or pushed together on the supports, then the pins are removed and replaced with bolts. The figure depicts the tooling and its use. To install an alignment pin in a bolt hole in a structural panel, the tapered end of the pin is inserted from one side of the panel, the cup is placed over the pin on the opposite side of the panel, the draw bolt is inserted through the cup and threaded into the pin, the draw bolt is tightened to pull the pin until the pin is seated firmly in the hole, then the draw bolt and cup are removed, leaving the pin in place. To remove an alignment pin, the cup is placed over the pin on the first-mentioned side of the panel, the draw bolt is inserted through the cup and threaded into the pin, then the draw bolt is tightened to pull the pin out of the hole.
Campbell, Oliver C.↗