Materials & Manufacturing

Conventional filament extrusion processes are unsuitable for recycling materials on the International Space Station due to requirements for continuous monitoring and tuning, as well as poor filament dimensional control. The Positrusion process recycles scrap or waste thermoplastics into filament for 3D...

The Orion Crew Module has a pressurized cabin of approximately 20 m3 in volume. There are a number of cold plates within the Crew Module for thermal management. An optical communication type of payload...

Current cryogenic insulation materials suffer from various drawbacks including high cost and weight, lack of structural or load-bearing capability, fabrication complexity, and property anisotropy. A need clearly exists for lightweight thermal insulation that is isotropic and...

A versatile, novel, multifunctional hybrid structural composite of a high-hydrogen epoxy matrix (UN-10) coupled with boron and carbon fibers (IM-7) has been developed. Prototype laminates of 18×18 in. (≈46×46 cm), with the nominal areal density of 0.35 g/cm2, were fabricated in this...

This innovation provides for significantly improved protection from micrometeoroid and orbital debris (MMOD) particles, and reliably determines the location, depth, and extent of MMOD impact damage.

Metering structures of remote sensing instruments often have large openings or access holes. Shear panels that are X-shaped, such as those proposed for the Neutron Star Interior Composition Explorer (NICER), generally consist of C-channels and L-brackets to minimize...

Laser absorption spectroscopy has emerged as one of the most important applications for semiconductor quantum cascade (QC) lasers, particularly in the mid-infrared spectral regime where many gases of interest exhibit fundamental absorption features. Laser absorption...

The development of a conformal nanotube process is enabling for many applications in solar physics and space astrophysics (e.g., direct detection and imaging of exoplanets). Coronagraphs are key heliophysics instruments because they image coronal mass ejections (CMEs), which are the most energetic...

Ion optics, or grids, for ion thrusters or ion sources are traditionally made by subtractive manufacturing methods such as milling/drilling or chemically etching holes from thin sheets of bulk material. This innovation uses additive manufacturing (AM), or 3D printing, to build the grids from...

ISAAC (Instrument Shared Artifact for Computing) offers adaptability, computation power, I/O bandwidth, digital interface standards, and data processing capability in a single, common, low-mass/power, and small-form-factor platform with significantly reduced, nonrecurring cost and risk...

A new class of phenolic and carbon-fiber-reinforced phenolic composites has been developed for thermal protection systems. The new materials have the advantage of being lightweight, strong, and tough, yet heat resistant and flexible. They retain excellent mechanical strength at high...

A multi-functional composite laminate material has been developed for structural and thermal applications for use in durable cryogenic fuel tanks for transportation vehicles and/or in the construction of habitats. The technology focuses on aerogel and fiber...

An improved class of alumoxanes and a method of synthesizing them have been invented. Alumoxanes are aluminum oxy hydroxide particles that have been modified with compounds containing carboxylic acid groups. For typical applications in which alumoxanes are required to...

NASA has an ongoing need for high-temperature solid lubricant coatings to reduce friction and wear in turbine engines, rocket engines, and other mechanical systems. Such lubricants must be thermally and chemically stable in air, vacuum, and reducing environments like hydrogen. Traditional...

Thin film, piezoelectric materials generate a small voltage whenever they are deformed, suggesting that they are suitable for tapping energy from freely available resources, such as the wind. Yet their low-energy production levels and lack of...

Utilization of CO2 to produce life support consumables, such as water and oxygen, offers a potential advance for NASA’s cabin atmosphere revitalization system and in-situ resources utilization concepts for long-term manned space missions. Toward...

Optical component fabrication using metals or ceramic materials involves many grinding and/or machining and polishing steps to achieve the proper form to the tolerances of imaging or photonic focusing instruments. These instruments range from infrared sensors, through visible and...

This innovation is a concept for a novel thermal architecture that would enable a day-long surface mission on Venus. A Venus lander mission could last much longer than a few hours on the surface of the planet by absorbing heat from the Venus environment, and from the electronics within the lander,...

Ongoing work in the development and characterization of sensory materials requires the development of shape memory alloy (SMA) powder or particles. These are embedded in structural material so that the progression of localized damage that occurs during fatigue crack growth will...

Solar energy has attracted keen attention because it is a unique, clean, and sustainable energy resource. It is also widely utilized as a power source in space exploration. A lightweight, durable, deployable, and highly efficient all polymer-based solar power panel was developed...

Currently, lead and lead-based materials are used to fabricate shields not only for X-rays, but also for other types of radiation. With the growing environmental concern about the toxicity of lead, and the high costs associated with transporting heavy lead-based shields in spacecraft, alternatives are needed...