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NASA 2014 STTR II Solicitation

SMALL BUSINESS CONCERN: (Firm Name, Mail Address, City/State/ZIP, Phone)
Streamline Numerics, Inc.
3221 North West 13th Street, Suite A
Gainesville, FL 32609-2189
(352) 271-8841

RESEARCH INSTITUTION: (RI Name, Mail Address, City/State/ZIP, Phone)
Stanford University
3160 Porter Drive, Suite 100
Palo Alto, CA 94304-8445
(650) 725-5966

PRINCIPAL INVESTIGATOR/PROJECT MANAGER: (Name, E-mail, Mail Address, City/State/ZIP, Phone)
Siddharth Thakur
st@snumerics.com
3221 North West 13th Street, Suite A
Gainesville,  FL 32609-2189
(352) 271-8841

Estimated Technology Readiness Level (TRL) at beginning and end of contract:
Begin: 3
End: 6

TECHNICAL ABSTRACT (LIMIT 200 WORDS)
The innovation proposed here is a high-performance, high-fidelity simulation capability for simulating liquid rocket spray combustion based on a novel spray-flamelet methodology which will be integrated into Loci-STREAM which is a CFD solver developed by the proposing personnel under funding from NASA over the last several years. A new spray-flamelet formulation will be incorporated into Loci-STREAM. The particular advantages of this formulation are (i) its consistency with the single-phase flamelet-formulation (already available in Loci-STREAM), (ii) its formulation in mixture-fraction space, overcoming the non-uniqueness of the classical mixture-fraction parameterization, and (iii) its applicability to finite Stokes-number, thereby accounting for particle evaporation, slip-velocity, and poly-dispersed spray-phase. The flamelet methodology already available in Loci-STREAM – in conjunction with Hybrid RANS-LES (HRLES) methodology – has facilitated an order of magnitude improvement in simulation turnaround times for NASA applications involving complex physics in 3D geometries. This project is aimed at extending this flamelet methodology to spray combustion resulting in a state-of-the-art design and analysis tool to enable accurate, fast and robust simulations of multiphase combustion in liquid rocket engines (involving liquid propellants such as LOX and LH2/LCH4/RP-1/RP-2), combustion stability analysis, etc. which constitute critical components of NASA's upper stage launch propulsion systems.

POTENTIAL NASA COMMERCIAL APPLICATION(S) (LIMIT 150 WORDS)
The computational tool resulting from this project will have wide-ranging commercial applications. The Hybrid RANS-LES methodology can be used for a wide variety of engineering applications involving unsteady turbulent flows. The reacting flow capability can be used for simulating combusting flows in various industrial applications, such as gas turbine engines, diesel engines, etc. The real-fluids methodology can be used in a large number of industrial flow situations involving both chemically inert and reacting flows. With additions of multi-phase spray combustion modeling capability, the applicability of this tool can be further broadened.

POTENTIAL NON-NASA APPLICATION(S) (LIMIT 150 WORDS)
The outcome of Phase 2 activities will be a powerful CFD-based design and analysis tool for propulsion engines of relevance to NASA. This tool is envisioned to be useful for full rocket engine simulations, injector design, etc. Specific applications at NASA of this capability include: (a) high-fidelity simulations of nano-launcher upper stage propulsion systems, (b) design improvements of injectors of J-2X and RS-68 engines as well as potential novel designs to be developed for NASA's proposed heavy lift vehicle, (c) modeling of multi-element injectors coupled with fuel and oxidizer feedlines and manifolds, (d) prediction of stability and stability margins, etc.

TECHNOLOGY TAXONOMY MAPPING
Software Tools (Analysis, Design)
Spacecraft Main Engine

SMALL BUSINESS CONCERN: (Firm Name, Mail Address, City/State/ZIP, Phone)
Gloyer-Taylor Laboratories, LLC
112 Mitchell Boulevard
Tullahoma, TN 37388-4002
(931) 455-7333

RESEARCH INSTITUTION: (RI Name, Mail Address, City/State/ZIP, Phone)
University of Tennessee Space Institute
411 BH Goethert Pkwy
Tullahoma, TN 37388-9700
(931) 393-7351

PRINCIPAL INVESTIGATOR/PROJECT MANAGER: (Name, E-mail, Mail Address, City/State/ZIP, Phone)
Paul Gloyer
paul.gloyer@gtlcompany.com
112 Mitchell Boulevard
Tullahoma,  TN 37388-4002
(931) 455-7333

Estimated Technology Readiness Level (TRL) at beginning and end of contract:
Begin: 3
End: 6

TECHNICAL ABSTRACT (LIMIT 200 WORDS)
GTL has been developing a suite of transformational technologies that have the capability to disrupt the traditional launch vehicle paradigm. BHL composite cryotank technology provides a four times improvement over large aluminum iso-grid tanks, offering a 6 percentage point improvement in small stage PMF. Superior Stability Engine is an innovative liquid rocket engine configured to maximize combustion stability margin while also maximizing engine performance. NORPS is a non-helium gas generator system that can be used to pressurize the propellant tanks for 1/3 the mass and 1/10 the volume of a comparable helium based system. Using these and other technologies, GTL has developed the conceptual design for the Advanced Cryogenic Expendable (ACE) nano-launch vehicle. The 7700 lb gross lift-off weight ACE vehicle is capable of delivering a 154 lb payload to 400 nmi circular orbit at 28.5 deg inclination. With a launch cost of less than $1M at low launch rate, ACE is directly competitive with existing large launch vehicles on a $/lb basis. This affordability is enabled by a combination of high performance, reduced stages and parts count, and simplified operations. The proposed Phase II effort will seek to reduce the ACE vehicle development risk by increasing the technology readiness level of critical technologies. Specifically, GTL will fabricate and test a prototype NORPS gas generator and pressurization system. Along with this, GTL shall fabricate a full-scale BHL composite cryotank for use in the system testing using modular manufacturing techniques. The integrated system shall be tested for operational capabilities to demonstrate the effectiveness of the technology and optimize the system design. The data from these tests will be used to refine and optimize the design of the ACE vehicle.

POTENTIAL NASA COMMERCIAL APPLICATION(S) (LIMIT 150 WORDS)
The ACE nano-launch system would provide commercial and DoD customers with an affordable means to launch small payloads to orbit that is competitive with large launch vehicles. As a small launch vehicle with the capability of austere operations, ACE can be used to provide DoD with tactical launch capability that can be used to increase resiliency of US military space assets. Additionally, the affordability of ACE would allow it to be adapted for weapons delivery, thereby providing low-cost global strike capability. The suite of ACE technologies can be used to upgrade commercial and DoD space launch systems. Several commercial launch vehicle developers are already considering BHL cryotanks for their vehicles. The Air Force is currently considering the UCDS and SSE technologies for insertion into their Oxygen Rich Staged Combustion engine development effort. The Missile Defense Agency is considering using the UCDS technology to improve the stability and performance of missile defense systems.

POTENTIAL NON-NASA APPLICATION(S) (LIMIT 150 WORDS)
The ACE nano-launch vehicle offers small payload launch capability for a cost that is competitive on a $/kg basis with that of large launch vehicles. This represents more than an order of magnitude improvement in affordability over what can be achieved with existing small launch vehicles. This launch capability would provide NASA with the means to affordably launch numerous small scientific and exploratory spacecraft, without having to bundle them together on large launch vehicles. This will provide NASA with enhanced flexibility in mission design that will increase space mission effectiveness. When the ACE vehicle design is eventually scaled to heavy-lift size, the cost of payload delivery to orbit would be reduced to less than $500/kg to LEO. This would represent an order of magnitude improvement in affordability compared to existing large heavy-lift launch vehicles. This level of launch affordability would enable large scale access to space that would facilitate permanent habitation of the Moon and Mars. In the near term, the suite of ACE technologies can be used to upgrade NASA space systems. For instance, the NORPS non-helium pressurization system could be used to reduce helium use on Orion and SLS. The high performance BHL cryotanks could be used to improve performance of SLS and other NASA vehicles under development. The Superior Stability Engine technology could be used to reduce development costs for new NASA engines.

TECHNOLOGY TAXONOMY MAPPING
Space Transportation & Safety
Pressure & Vacuum Systems
Structures
Vehicles (see also Autonomous Systems)
Fuels/Propellants
Launch Engine/Booster
Hardware-in-the-Loop Testing
Nondestructive Evaluation (NDE; NDT)
Cryogenic/Fluid Systems
Diagnostics/Prognostics

SMALL BUSINESS CONCERN: (Firm Name, Mail Address, City/State/ZIP, Phone)
Lynntech, Inc.
2501 Earl Rudder Freeway South
College Station, TX 77845-6023
(979) 764-2218

RESEARCH INSTITUTION: (RI Name, Mail Address, City/State/ZIP, Phone)
University of Texas at Dallas
800 West Campbell Road
Richardson, TX 75080-3021
(972) 883-6530

PRINCIPAL INVESTIGATOR/PROJECT MANAGER: (Name, E-mail, Mail Address, City/State/ZIP, Phone)
Anuncia Gonzalez-Martin
anuncia.gonzales-martin@lynntech.com
2501 Earl Rudder Freeway South
College Station,  TX 77845-6023
(979) 764-2200

Estimated Technology Readiness Level (TRL) at beginning and end of contract:
Begin: 3
End: 6

TECHNICAL ABSTRACT (LIMIT 200 WORDS)
NASA emphasizes the need to implement energy harvesting in its future mission activities, as well as to conserve on energy and to enhance the sustainability of NASA's facilities. By harvesting energy from the ambient surroundings, there is less dependence on a primary power supply (e.g., combustion engines, fuel cells, batteries, solar cells, etc., and even AC electricity for ground applications), and a possibility for independent operation of assorted electronic and mechanical devices, including remote and wireless sensors. Differential heat sources are very abundant, both in ground and space scenarios. For this STTR application, Lynntech has teamed up with Dr. Ray Baughman (Director of NanoTech Institute, University of Texas at Dallas) to pioneer the use of artificial muscles (also known as coiled polymer actuators) as an advanced method for energy harvesting. The proposed innovative technology for efficient capture and conversion of thermal energy is very versatile: it can convert heat into mechanical and electrical energy, and it can heat harvest under typical ambient environments, under high intensity energy environments (as found in propulsion testing and launch facilities), and under cryogenic temperatures. Therefore, the proposed technology can be adapted for use in multiple space and ground applications for heat capture and conversion.

POTENTIAL NASA COMMERCIAL APPLICATION(S) (LIMIT 150 WORDS)
The proposed technology will provide a valuable supply of mechanical and electrical power obtained from harvesting waste heat from diverse sources such as jet engines, vehicle engines, rocket engines, exhaust pipes, microchips, solar cells, warm soils, power stations, boilers, cooling towers, power plants, oil refineries, steel manufacturing, glass and brick manufacturing, gas pipelines, compressors, furnaces, ovens, incinerators, refrigerators, electronic devices, etc. This in turn will reduce the net power consumption. Market sectors with attractiveness for waste heat recovery include oil and gas extraction, petroleum and coal products manufacturing, chemical plants, pulp and paper mills, steel, metal, glass, and brick manufacturing, etc. It can power multiple electronic devices (including wireless sensors) and operate diverse mechanical devices (including valves and thermal switches). Of special interest is heat waste harvested in remote locations, helping to provide independence from the electric grid.

POTENTIAL NON-NASA APPLICATION(S) (LIMIT 150 WORDS)
The expected outcome of the Phase II will allow applying this technology to NASA's roadmap in the area of Space Power and Energy Storage (SPES) (Energy Harvesting is listed under Power Generation) for Exploration Systems Mission Directorate, Space Operations Mission Directorate, and Aeronautics Mission Directorate. In addition, the National Research Council has identified "Increase Available Power" as a NASA Top Technical Challenge. Also, a NASA Grand Challenge is "Affordable and Abundant Power" for NASA mission activities. As such, novel energy harvesting technologies are critical toward supporting future power generation systems to begin to meet these challenges. NASA has many unique needs for power that require special technology solutions due to extreme environmental conditions. These missions would benefit from the proposed versatile, advanced thermal energy harvesting technology. It will provide valuable mechanical and electrical energy from heat harvesting from diverse sources (both in space and terrestrial) to power multiple electronic devices and operate diverse mechanical devices. Additionally, the proposed technology will help enhancing the sustainability of NASA's facilities.

TECHNOLOGY TAXONOMY MAPPING
Space Transportation & Safety
Conversion
Actuators & Motors
Cryogenic/Fluid Systems
Diagnostics/Prognostics

SMALL BUSINESS CONCERN: (Firm Name, Mail Address, City/State/ZIP, Phone)
Extreme Diagnostics, Inc.
6960 Firerock Court
Boulder, CO 80301-3814
(303) 523-8924

RESEARCH INSTITUTION: (RI Name, Mail Address, City/State/ZIP, Phone)
The Regents of the University of Michigan
3003 South State Street
Ann Arbor, MI 48109-1274
(734) 764-7250

PRINCIPAL INVESTIGATOR/PROJECT MANAGER: (Name, E-mail, Mail Address, City/State/ZIP, Phone)
Robert Owen
rowen@extremediagnostics.com
6960 Firerock Court
Boulder,  CO 80301-3814
(303) 523-8924

Estimated Technology Readiness Level (TRL) at beginning and end of contract:
Begin: 5
End: 6

TECHNICAL ABSTRACT (LIMIT 200 WORDS)
This STTR project delivers a compact vibration-based Energy Conversion Module (ECM) that powers sensors for purposes such as structural health monitoring (SHM). NASA customers include the Rocket Propulsion Test (RPT) program, the ISS, and the Orion deep space vehicle, all of which need wireless sensors to monitor and assess structural health. The ECM represents a major advancement in the use of wireless and self-powered devices by enabling the miniaturization of vibration-based energy harvesting devices suitable for powering sensors. Implications of the innovation There exist two basic problems in reducing the size of vibration-based harvesters that plague all current commercially available devices—both are addressed here. The first is addressed by eliminating the problem of frequency matching in compact devices. The second is addressed by providing a broadband device capable of energy conversion across a range of frequencies. Technical objectives Our existing prototype is a TRL 5 unit that we used to demonstrate our ability to convert kinetic energy to useful electrical power. This prototype combines piezoelectric beam transducers with artificially induced magnetic fields to force a nonlinear broadband behavior. Phase II uses this approach for compact sizing of low center frequency transducers with the objective of delivering a field-validated compact ECM that provides a near order-of-magnitude improvement over current energy harvesters. Research description Phase I created an efficient prototype and established feasibility. In Phase II we build a fully operational unit and perform field validation-tests compatible with SSC test beds. Anticipated results Anticipated results include a reduction in the amount of battery waste generated by self-powered devices that enables long-term wireless deployment. Phase I completed a TRL 5 prototype and tested its performance in relevant vibration environments. Phase II validates and delivers a TRL 6 unit.

POTENTIAL NASA COMMERCIAL APPLICATION(S) (LIMIT 150 WORDS)
The current market is seeing increased communication between equipment within an intelligent network that can automatically manage tasks in smart buildings, logistics, and monitoring. Within this so-called "Internet of Things" (IoT) the majority of sensors and devices will eventually be connected to other devices and the Internet. Implementing this vision requires portable devices that can be applied wherever needed, which introduces a significant challenge—how can these millions of distributed devices be powered? One path to success is energy harvesting wireless technology. Furthermore, the current dependence on batteries to power pacemakers, defibrillators, and other medical devices raise numerous safety and reliability concerns. Energy harvesting promises to eliminate bulky batteries and the risk of battery-related defects. Besides medical, applications for wireless sensors include Homeland Security structural analysis to mitigate threats (preparedness) and assess damage (response), smart structures, and SHM of civil and military structures. This broader impact includes widespread monitoring with the potential for preventing catastrophic failures and saving lives. Civil structures include bridges, highway systems, buildings, power plants, underground structures, and wind energy turbines (alternative and renewable energy). SHM applications are also driven by a desire to lower costs by moving from schedule-based to condition-based maintenance.

POTENTIAL NON-NASA APPLICATION(S) (LIMIT 150 WORDS)
Energy consumption is now often the most significant problem discussed whenever technology is considered. As the energy efficiency of computational devices increases, self-power via harvested energy becomes increasingly viable for a host of electronic devices for sensing and other applications. The ECM kinetic energy harvester provides self-power for a variety of wireless sensors that include those for in situ SHM of NASA vehicles and infrastructure like that supporting the RPT program. ECM directly supports non-destructive evaluation (NDE) systems for safety assurance of future vehicles. There is a major effort within NASA, the FAA, and the military to develop integrated vehicle health management (IVHM) technology that uses SHM information for computer controlled recovery actions aimed at avoiding catastrophe. ECM provides enabling technology for this effort. ECM supports the NASA Engineering and Safety Center with tools for independent testing, analysis, and assessment of high-risk projects. NASA applications include self-health monitoring of future exploration vehicles and support structures like habitats and Composite Overwrapped Pressure Vessels (COPVs). ECM-powered sensors reduce maintenance, minimize crew interaction, and reduce spaceflight technical risks and needs. ECM is directly responsive to Topic T3.01, which calls for innovative and compact systems to harvest and convert kinetic energy sources.

TECHNOLOGY TAXONOMY MAPPING
Space Transportation & Safety
Conversion
Distribution/Management
Generation
Sources (Renewable, Nonrenewable)
Storage
Quality/Reliability
Smart/Multifunctional Materials
Structures
Sensor Nodes & Webs (see also Communications, Networking & Signal Transport)

SMALL BUSINESS CONCERN: (Firm Name, Mail Address, City/State/ZIP, Phone)
M4 Engineering, Inc.
4020 Long Beach Boulevard
Long Beach, CA 90807-2683
(562) 981-7797

RESEARCH INSTITUTION: (RI Name, Mail Address, City/State/ZIP, Phone)
Virginia Polytechnic Institute
300 Turner Street Northwest
Blacksburg, VA 24061-0001
(540) 231-4881

PRINCIPAL INVESTIGATOR/PROJECT MANAGER: (Name, E-mail, Mail Address, City/State/ZIP, Phone)
Myles Baker
mbaker@m4-engineering.com
4020 Long Beach Boulevard
Long Beach,  CA 90807-2683
(562) 305-3391

Estimated Technology Readiness Level (TRL) at beginning and end of contract:
Begin: 4
End: 5

TECHNICAL ABSTRACT (LIMIT 200 WORDS)
In aircraft design, reducing structural weight is often a prime objective, while various constraints in multiple disciplines, such as structure, aerodynamics and aeroelasticity should be imposed on the aircraft. Therefore, engineers need optimization tools to incorporate the multidisciplinary constraints using appropriate fidelity during the early stages of concept design. Classic structural design of aircraft structures is based on the concept of a "wing box" that uses simple components such as straight spars and ribs, quadrilateral wing skin panels and straight stiffeners. A new design philosophy, using curvilinear SpaRibs has been introduced based on emerging manufacturing technologies such as Electron Beam Free Form Fabrication and Friction Stir Welding (FSW). In those innovative technologies, the wing structure is manufactured as an integrated part instead of using mechanically fastened structural components. This design approach makes it possible to design curved substructure that is a hybrid between spars and ribs, therefore called "SpaRibs". These can be designed to have favorable coupling between bending and torsion, and can improve the buckling resistance of local panels. The ability to tailor the bend-twist coupling has been shown to offer substantial improvement in aeroelastic behavior without a weight penalty (or alternately, a weight savings without aeroelastic problems). In this program we will advance this technology to a TRL of 5-6 (or to 6-7 in a Phase III) by designing a subsonic transport wing with better aeroelastic and aeroservoelastic performance, and by designing a test article and test program suitable for proving the performance benefits in flight.

POTENTIAL NASA COMMERCIAL APPLICATION(S) (LIMIT 150 WORDS)
As with the NASA applications, this technology increases aircraft performance for multiple classes of aircraft, so this technology may be applied to aircraft including subsonic transports, UAV's, fighters, supersonic transports, bombers, military transports, and reconnaissance aircraft. A successful flight test program in Phase III could pave the way to widespread adoption of this technology (in whole or in part) by Boeing, Northrop-Grumman, Lockheed-Martin, and a host of smaller airframers.

POTENTIAL NON-NASA APPLICATION(S) (LIMIT 150 WORDS)
This technology has the potential to improve the performance of aircraft in subsonic, transonic, and supersonic flight regimes, especially those vehicles whose performance is significantly impacted by aeroelastic phenomena such as flutter or unfavorable static aeroelastic interactions. As such, this could impact any NASA-sponsored aircraft program. The most immediate application would be to the X-56A program, but follow on applications are likely to include future technology demonstration aircraft such as low-boom demonstrators, HALE configurations, planetary exploration aircraft, etc.

TECHNOLOGY TAXONOMY MAPPING
Aerodynamics
Models & Simulations (see also Testing & Evaluation)
Software Tools (Analysis, Design)
Structures
Vehicles (see also Autonomous Systems)

SMALL BUSINESS CONCERN: (Firm Name, Mail Address, City/State/ZIP, Phone)
Tao of Systems Integration, Inc.
1100 Exploration Way
Hampton, VA 23666-1339
(757) 220-5040

RESEARCH INSTITUTION: (RI Name, Mail Address, City/State/ZIP, Phone)
The Texas A&M Engineering Experiment Station
400 Harvey Mitchell Parkway South, Suite 300
College Station, TX 77845-4375
(979) 845-6733

PRINCIPAL INVESTIGATOR/PROJECT MANAGER: (Name, E-mail, Mail Address, City/State/ZIP, Phone)
Arun Mangalam
arun@taosystem.com
1100 Exploration Way
Hampton,  VA 23666-1339
(757) 220-5040

Estimated Technology Readiness Level (TRL) at beginning and end of contract:
Begin: 4
End: 6

TECHNICAL ABSTRACT (LIMIT 200 WORDS)
Control of extremely lightweight, long endurance aircraft poses a challenging aeroservoelastic (ASE) problem due to significantly increased flexibility, and aerodynamic, structural, and actuator nonlinearities. To obtain the benefits of increased aerostructural efficiency, the controller needs to trim at a specified optimal shape while minimizing structural fatigue from gust disturbances. Tao Systems, Texas A&M University and University of Minnesota propose to develop a distributed, passivity-based, ASE controller (DPASC) using sectional aerodynamic and structural output-only feedback. This scalable approach has the potential to minimize the impact of aerodynamic / structural uncertainties and control surface free-play / saturation, while guaranteeing global asymptotic stability.

POTENTIAL NASA COMMERCIAL APPLICATION(S) (LIMIT 150 WORDS)
The ability to cruise efficiently at a range of altitude, enabled by a substantial increase in cruise lift-to-drag (L/D) ratios over today's high-altitude aircraft, provides sustained presence and long range. Aerodynamic load/moment sensors would enable the efficient, robust active control of adaptive, lightweight wings to optimize lift distribution to maximize L/D. Cost-effectively improving the energy capture and reliability of wind turbines would help national renewable energy initiatives. A standalone aerodynamic load/moment sensor could provide output for control feedback to mitigate the turbine blade lifetime-limiting time varying loads generated by the ambient wind.

POTENTIAL NON-NASA APPLICATION(S) (LIMIT 150 WORDS)
The benefits of a distributed, passivity-based ASE system that we are proposing has a number of benefits: (1) addresses nonlinearities in aerodynamics, structures, and actuation, (2) increases controller robustness: reduces dependency on aerodynamic and structural uncertainties, (3) increases aerostructural efficiency, (4) enables mission persistence at a lower cost. For example, degradation due to atmospheric effects such as moisture and fatigue caused by constant wing stresses provides significant risk over the life of a HALE-type UAV, e.g., DARPA Vulture. Longevity of components is also a major technological risk. Using extremely high aspect ratios reduces drag. The system can utilize dynamic soaring for further aerodynamic efficiency. The system can adapted for using optimal control for efficient path planning or gaining aerodynamic advantages through formation flight.

TECHNOLOGY TAXONOMY MAPPING
Aerodynamics
Air Transportation & Safety
Avionics (see also Control and Monitoring)
Autonomous Control (see also Control & Monitoring)
Recovery (see also Vehicle Health Management)
Algorithms/Control Software & Systems (see also Autonomous Systems)
Attitude Determination & Control
Vehicles (see also Autonomous Systems)
Diagnostics/Prognostics
Recovery (see also Autonomous Systems)

SMALL BUSINESS CONCERN: (Firm Name, Mail Address, City/State/ZIP, Phone)
Honeybee Robotics Ltd.
P.O.Box 27420
Brooklyn, NY 11202-7420
(212) 966-0661

RESEARCH INSTITUTION: (RI Name, Mail Address, City/State/ZIP, Phone)
Embry-Riddle Aeronautical University
600 South Clyde Morris Boulevard
Daytona Beach, FL 32114-3900
(386) 226-6000

PRINCIPAL INVESTIGATOR/PROJECT MANAGER: (Name, E-mail, Mail Address, City/State/ZIP, Phone)
Hever Moncayo
moncayoh@erau.edu
600 S. Clyde Morris Boulevard
Daytona Beach,  FL 32114-3900
(386) 226-7953

Estimated Technology Readiness Level (TRL) at beginning and end of contract:
Begin: 4
End: 5

TECHNICAL ABSTRACT (LIMIT 200 WORDS)
In Phase 2 we will develop a fully integrated, autonomous free-flying robotic system based on a commercial SkyJib quadcopter, and demonstrate flying straight and level to a target location, acquisition of rock and regolith samples, and return to the point of origin. The work plan for Phase 2 is as follows: 1. Completion of the Guidance, Navigation, Control, Vision, and Sample Acquisition subsystems. 2. Integration of all the payload elements at ERAU and system level check out 3. Demonstration of the entire system at NASA KSC 4. Field deployment at analog location

POTENTIAL NASA COMMERCIAL APPLICATION(S) (LIMIT 150 WORDS)
Sampling of contaminated soils and liquid from hazardous environments (nuclear reactors, chemical spills etc.). Geologists could use it to capture samples from hard to reach areas, such as for example lava-tubes in Hawaii. Cameras and sensors could map the area and give the geological context. Commercial companies such as Planetary Resources and Deep Space Industries, who are interested in asteroid mining for economic gains, could also use this technology.

POTENTIAL NON-NASA APPLICATION(S) (LIMIT 150 WORDS)
In 2010, President Obama called for a new approach to space exploration, which would include human and robotic exploration of asteroids. The first step in this program would be Asteroid Retrieval Mission (ARM) currently under study at NASA. Characterization of these objects would require novel approaches akin to what is here proposed. In the latest Decadal Survey, the committee recommended selecting a Comet Surface Sample Return mission as one of the NF4 missions.

TECHNOLOGY TAXONOMY MAPPING
Navigation & Guidance
Relative Navigation (Interception, Docking, Formation Flying; see also Control & Monitoring; Planetary Navigation, Tracking, & Telemetry)
Spacecraft Design, Construction, Testing, & Performance (see also Engineering; Testing & Evaluation)
Spacecraft Instrumentation & Astrionics (see also Communications; Control & Monitoring; Information Systems)
Tools/EVA Tools
Autonomous Control (see also Control & Monitoring)
Perception/Vision
Robotics (see also Control & Monitoring; Sensors)

SMALL BUSINESS CONCERN: (Firm Name, Mail Address, City/State/ZIP, Phone)
Omega Optics, Inc.
8500 Shoal Creek Boulevard, Building 4, Suite 200
Austin, TX 78757-7591
(512) 996-8833

RESEARCH INSTITUTION: (RI Name, Mail Address, City/State/ZIP, Phone)
Texas State University
601 University Drive
San Marcos, TX 78666-4684
(512) 245-2102

PRINCIPAL INVESTIGATOR/PROJECT MANAGER: (Name, E-mail, Mail Address, City/State/ZIP, Phone)
Harish Subbaraman
harish.subbaraman@omegaoptics.com
8500 Shoal Creek Boulevard, Building 4, Suite 200
Austin,  TX 78757-7591
(512) 996-8833

Estimated Technology Readiness Level (TRL) at beginning and end of contract:
Begin: 3
End: 6

TECHNICAL ABSTRACT (LIMIT 200 WORDS)
Communication technologies support all NASA space missions, among which autonomous communication technologies are extremely beneficial to future missions, including the Asteroid Redirect Mission, and human expedition to Mars and beyond. Low-cost, high gain, light-weight, and flexible active antenna systems are highly desired. In this program, we propose to develop a fully flexible ink-jet printed monolithic graphene-based high frequency PAA communication system. The superior electronic, optical, mechanical, and thermal properties offered by graphene (carrier mobility ~ 200,000cm^2/V.s; optical transparency ~ 98%; high current density ~ 10^8A/cm^2; thermal conductivity ~ 5000W/mK) is expected to significantly enhance the system features compared to the state-of-the-art flexible antenna systems., with operating frequency in excess of 100GHz expected. In Phase I, we printed graphene field-effect transistors and demonstrated a high (38:1) On/Off ratio. Graphene patch antennas were demonstrated with higher gain than silver. Results also indicated the feasibility of reducing the antenna size for a given frequency without sacrificing the gain. Finally, a 2-bit 1x2 graphene PAA was fully printed, and beam steering of a 4GHz RF signal from 0 to 42.4 degrees was demonstrated. The antenna system also showed good stability and tolerance after 5500 bending cycles. In Phase II, the graphene material inks will be further optimized for achieving high performance FETs and conductive films. A fully packaged 4-bit 2D 4x4 S-band PAA on a flexible substrate will be developed, and performance features, including gain/efficiency, frequency range, bandwidth, power consumption, and lifetime/reliability, will be characterized. Additionally, a roll-to-roll process to scale-up production will be developed, and the feasibility of large antenna array manufacturing at low-cost will be demonstrated.

POTENTIAL NASA COMMERCIAL APPLICATION(S) (LIMIT 150 WORDS)
Our high-frequency graphene-FET and ink-jet printing technology, apart from being valuable to NASA, can also be of commercial value to Non-NASA applications requiring ultra-sensitive and standalone devices. The commercial applications include: 1. RF identification tags; 2. Smart cards; 3. Electronic papers; 4. Large area flat panel displays and lighting; 5. Sensors; 6. Flexible large area solar cells and batteries; 7. Communication systems;

POTENTIAL NON-NASA APPLICATION(S) (LIMIT 150 WORDS)
(1) Active phased-array antenna: The flexible graphene-FET is an enabling technology for the construction of high-performance large-area flexible electronics that can be monolithically integrated with deployable antennas and provide distributed control, processing, and reconfiguration functions to achieve active and smart flexible/wearable and conformal antenna systems with enhanced functionalities. (2) High gain, frequency agile, multi-band reconfigurable antenna: The high-speed flexible electronics circuits offer embedded control and reconfiguration functions to achieve the desired gain and band-selection capabilities. (3) High power electronics: Graphene has carrier mobility exceeding 200,000 cm^2/V.s and has a large current-density carrying capacity of ~10^8 A/cm^2. Such a large current carrying capability allows this fully-printed transistor technology to be used in NASA's high power electronics applications. Overall, our technology will provide advanced navigation and communication in order to support several current and future NASA missions, including the asteroid redirect mission, human expedition to Mars, deep space exploration beyond low earth orbit, etc.

TECHNOLOGY TAXONOMY MAPPING
Autonomous Control (see also Control & Monitoring)
Antennas
Telemetry/Tracking (Cooperative/Noncooperative; see also Planetary Navigation, Tracking, & Telemetry)
Circuits (including ICs; for specific applications, see e.g., Communications, Networking & Signal Transport; Control & Monitoring, Sensors)
Manufacturing Methods
Materials (Insulator, Semiconductor, Substrate)
Nanomaterials

SMALL BUSINESS CONCERN: (Firm Name, Mail Address, City/State/ZIP, Phone)
HJ Science & Technology, Inc.
2929 Seventh Street, Suite 120
Berkeley, CA 94710-2753
(408) 464-3873

RESEARCH INSTITUTION: (RI Name, Mail Address, City/State/ZIP, Phone)
Lawrence Berkeley National Laboratory
One Cyclotron Road, 971-SP
Berkeley, CA 94720-0001
(510) 486-6306

PRINCIPAL INVESTIGATOR/PROJECT MANAGER: (Name, E-mail, Mail Address, City/State/ZIP, Phone)
Erik Jensen
erikjensen100@gmail.com
2929 Seventh Street, Suite 120
Berkeley,  CA 94710-2753
(925) 766-3997

Estimated Technology Readiness Level (TRL) at beginning and end of contract:
Begin: 4
End: 6

TECHNICAL ABSTRACT (LIMIT 200 WORDS)
HJ Science & Technology (HJS&T) and Lawrence Berkeley National Laboratory (LBNL) propose a highly integrated, programmable, and miniaturized microfluidic automation platform capable of running rapid and complex synthetic biology and bioengineering processes for engineering life supporting microbes in space exploration missions. Our approach combines the microfluidic automation technology of HJS&T with the novel synthetic biology technologies of 1) combinatorial gene library generation, 2) host transformation, and 3) gene product screening at LBNL and the Joint BioEnergy Institute (JBEI). In Phase I, we have established the feasibility of the proposed microfluidic automation technology by engineering and screening cyanobacterial cells for enhanced production of free fatty acids. In Phase II, we will expand the Phase I microfluidic automation capability to enable automated, metabolic engineering and screening of microbes for enhanced production of other classes of important compounds for in situ resource utilization in NASA space exploration missions: propellant fuels, biopolymers, and pharmaceuticals. We will also build and deliver a Phase II prototype. The successful development of the microfluidic automation technology with its automated and miniaturized platform will lay the groundwork for life supporting waste management and in situ resource utilization capabilities in future NASA manned space exploration missions.

POTENTIAL NASA COMMERCIAL APPLICATION(S) (LIMIT 150 WORDS)
Synthetic biology offers significant advancements in a broad range of commercial applications including biofuel production, drug development, and agricultural development. The utility of our microfluidic technology in diverse fields is further enhanced by the development of automation procedures for a suite of organisms including cyanobacteria, E. coli, and yeast. As such, the proposed technology could be used in engineering biological processes such as mass producing effective medications, manufacturing specialty chemicals, engineering organisms and enzymes for better biofuel production, or developing crops that are more resistant to pathogens or drought. Generating and screening multiple combinations of genes, enzymes, and other biological parts is also vital to biotechnology research and development.

POTENTIAL NON-NASA APPLICATION(S) (LIMIT 150 WORDS)
Microfluidic automation technology for synthetic biology offers significant opportunities for the development of life sustaining biological systems for long term space exploration missions. Among the potential applications are enhanced production of food and fuels from photosynthetic organisms, processing of waste products such as CO2 or urea, atmosphere regeneration, and water re-utilization as a part of environmental control and life support on the International Space Station. By engineering with new or enhanced metabolic pathways for the production or processing of chemical resources or waste, photosynthesis using cyanobacteria can be a particularly effective mechanism for environmental control and life support.

TECHNOLOGY TAXONOMY MAPPING
Analytical Methods
Biomass Growth
Essential Life Resources (Oxygen, Water, Nutrients)
Food (Preservation, Packaging, Preparation)
Waste Storage/Treatment
Sources (Renewable, Nonrenewable)
Fuels/Propellants

SMALL BUSINESS CONCERN: (Firm Name, Mail Address, City/State/ZIP, Phone)
Opto-Knowledge Systems, Inc. (OKSI)
19805 Hamilton Avenue
Torrance, CA 90502-1341
(310) 756-0520

RESEARCH INSTITUTION: (RI Name, Mail Address, City/State/ZIP, Phone)
Pacific Northwest National Laboratory (PNNL)
902 Battelle Blvd., 902 Battelle Blvd.
Richland, WA 99352-0999
(888) 375-7665

PRINCIPAL INVESTIGATOR/PROJECT MANAGER: (Name, E-mail, Mail Address, City/State/ZIP, Phone)
Jason Kriesel
jason@oksi.com
19805 Hamilton Ave
Torrance,  CA 90502-1341
(310) 756-0520

Estimated Technology Readiness Level (TRL) at beginning and end of contract:
Begin: 4
End: 6

TECHNICAL ABSTRACT (LIMIT 200 WORDS)
We propose to develop and demonstrate a new sensor platform for isotope and trace-gas analysis that is appropriate for future planetary missions. Among other applications, the technology can enable the collection of isotope ratio data in support of the search for evidence of life within the solar system. Current limitations to in-situ isotope measurements will be overcome by utilizing a capillary absorption spectrometer (CAS). This concept enables high precision measurements within the ultra-small volume (~ 0.1 ml) of a hollow fiber optic capillary and has proven to be three orders of magnitude more sensitive than competing sensors. The proposed effort focuses on transitioning the current lab-based technique to a small size, weight, and power (SWaP) device that can be operated unattended. In Phase I, proposed concepts for improving the system performance, reducing the SWaP, and engineering a field-capable device were proven and specific options down selected. Under Phase II, we will fully develop a general prototype sensor platform, which is applicable to a wide range of isotope ratio and trace-gas analysis applications. Specific examples of the utility and versatility of the concept will be demonstrated by using the system as a stand-alone gas sensor, as well as in combination with both a laser ablation sampler and a gas chromatograph. In addition, a dual laser system will be developed to measure both Carbon (C) and Sulfur (S) isotope ratios. The sensitivity afforded by the proposed system would open up remote analysis of smaller samples than ever before measured, which could be a significant development in the search for biosignatures on other planets and near space objects, as well as in the early Earth rock record.

POTENTIAL NASA COMMERCIAL APPLICATION(S) (LIMIT 150 WORDS)
The CAS sensor to be developed under this project will provide an extremely attractive alternative to both isotope ratio mass spectrometers (IRMS) and cavity ring down spectrometers (CRDS). The CAS will be relatively inexpensive, require only picomoles of material, and be much smaller than competing systems. CAS sensors will fill niche markets in forensic analysis, environmental sensing, human breath analysis, and industrial process control. This STTR will lead to a new class of sensors, not just a modification of an existing concept. The resulting ultra-small volume sensors could compete with and complement current commercial sensors, and potentially open up new opportunities to perform real-time, in-situ analysis of trace molecules and stable isotopes in remote and/or sample-limited situations.

POTENTIAL NON-NASA APPLICATION(S) (LIMIT 150 WORDS)
The isotope and gas sensor resulting from this project will be developed to support efforts to search for evidence of life on future NASA missions. The research is specifically relevant to NASA Objective 2.3 which is to "Ascertain the content, origin, and evolution of the solar system and the potential for life elsewhere," as well as NASA Astrobiology Roadmap Goal 7: "Determine how to recognize signatures of life on other worlds and on Earth." In fact, NASA Astrobiology Roadmap Objective 7.1 is to "Learn how to recognize and interpret biosignatures which, if identified in samples from ancient rocks on Earth or from other planets, can help to detect and/or characterize ancient and/or present-day life." The anticipated technology would also be useful for the exploration of the Moon, asteroids, primitive meteorites, comets, and interplanetary dust particles. The relatively small size of the system will enable it to be inserted into a range of missions including landers and rovers. The capillary absorption spectrometer (CAS) at the heart of the system will also provide a new high precision, ultra-low-volume sensor relevant to a range of other NASA applications. These include water isotope ratio measurements, atmospheric sensing of Earth and other planets, environmental sensing from a small UAV, analysis of soil bacteria related to Carbon cycle, as well as full elemental analysis of various microscopic-sized samples and organisms.

TECHNOLOGY TAXONOMY MAPPING
Analytical Instruments (Solid, Liquid, Gas, Plasma, Energy; see also Sensors)
Fire Protection
Lasers (Measuring/Sensing)
Biological Signature (i.e., Signs Of Life)
Chemical/Environmental (see also Biological Health/Life Support)
Optical/Photonic (see also Photonics)
Infrared

SMALL BUSINESS CONCERN: (Firm Name, Mail Address, City/State/ZIP, Phone)
Brimrose Technology Corporation
P.O. Box 616, 19 Loveton Circle
Sparks, MD 21152-9201
(410) 472-2600

RESEARCH INSTITUTION: (RI Name, Mail Address, City/State/ZIP, Phone)
University Of Maryland Baltimore County
1000 Hilltop Circle
Baltimore, MD 21250-0001
(410) 455-3140

PRINCIPAL INVESTIGATOR/PROJECT MANAGER: (Name, E-mail, Mail Address, City/State/ZIP, Phone)
Sudhir Trivedi
strivedi@brimrosetechnology.com
19 Loveton Circle
Sparks,  MD 21152-9201
(410) 472-2600

Estimated Technology Readiness Level (TRL) at beginning and end of contract:
Begin: 6
End: 8

TECHNICAL ABSTRACT (LIMIT 200 WORDS)
One of the strategic goals of NASA's Planetary Science Mission is to advance scientific knowledge of the origin and history of the solar system, the potential for life elsewhere. The current STTR addresses this strategic goal. The proto-type AOTF-based SWIR spectropolarimetric imaging system developed in Phase I (which will be further optimized and integrated with optimal algorithm/software in Phase II), will be a useful tool in determination of chemical composition and physical characteristics of planets of interest, short period comets, primitive meteorites and asteroid bodies, and in identifying the sources of simple chemicals important to prebiotic evolution and the emergence of life. The concept and proto-type instrument developed in this program operates as a hyper-spectral imager as well as a spectropolarimeter. It is capable of obtaining hyperspectral images and the polarization state at the pixel level. It is compact, rugged in nature, fully electronically controlled and has no moving parts. The images can be taken at any desired wavelength/s within the operational range, in any sequence. Hyperspectral data cubes will be collected using aforementioned systems. Before processing the spectral information in the data, system non-uniformity correction, spectral response correction, and atmospheric correction will be applied to the data.

POTENTIAL NASA COMMERCIAL APPLICATION(S) (LIMIT 150 WORDS)
The commercial product that will result from this work, an AOTF-based spectropolarimeter, has numerous non-NASA commercial applications. The spectropolarimetric system can be used in anomaly detection, countermine research, camouflage concealment and detection, and identification and discrimination of materials. Moreover, such a fast system will have varied applications in atmospheric monitoring and other commercial applications. The proposed electro- and acousto-optic will provide fast and real time information about the status of the atmosphere, thus the impact of human activities on the environment can be evaluated more quickly and more accurately. This device can help to facilitate the objectives of the Earth Science Enterprise (ESE) and the Earth Observing System (EOS). Thus the design and development of an imaging system as an outcome of the proposed research will have a multitude of applications in all sectors of life. Moreover, the instrumentation that will result from the proposed program will be immensely valuable for on-line process and feedback control and R&D in a wide variety of industries such as pharmaceuticals, chemicals, pulp and paper, biotechnology, just a name a few.

POTENTIAL NON-NASA APPLICATION(S) (LIMIT 150 WORDS)
There are a number of potential NASA applications for the AOTF-based spectropolarimetric imaging. These include material data basing, structural validation, combustion spectroscopy, non-destructive testing of space compliant parts, and qualification of time-sensitive materials in space. As more and more missions are undertaken involving landers, diverse and accurate databases of the spectral and polarimetric characteristics of various materials will be needed to quickly and accurately identify surface solid, liquid and gaseous materials. The spectral and polarimetric data obtained via 2-dimensional spectropolarimetric imaging can be used to view warping, small fractures and other deficiencies/issues that may occur in the structure of space based mission equipment. The 2-dimensional nature of AOTF based hyperspectral imaging allows for area spectral data collection during combustion events such as in ramjet and scramjet studies. Spectropolarimetric imaging allows for the non-contact, non-destructive analysis of the surface of components. And data models will allow the qualification of time sensitive consumable items in space. For instance, the potency of pharmaceuticals. The proposed device can also be used in various missions for in situ, non-destructive analysis of dust and icy surfaces, identification of organics, atmospheric radiometry, and rheology.

TECHNOLOGY TAXONOMY MAPPING
Image Processing
Data Acquisition (see also Sensors)
Data Modeling (see also Testing & Evaluation)
Data Processing
Detectors (see also Sensors)
Biological Signature (i.e., Signs Of Life)
Optical/Photonic (see also Photonics)
Infrared
Multispectral/Hyperspectral

SMALL BUSINESS CONCERN: (Firm Name, Mail Address, City/State/ZIP, Phone)
TIPD, LLC
1430 North 6th Avenue
Tucson, AZ 85705-6644
(520) 622-0804

RESEARCH INSTITUTION: (RI Name, Mail Address, City/State/ZIP, Phone)
University of Arizona, College of Optical Sciences
1630 East University Boulevard
Tucson, AZ 85721-0001
(520) 621-6997

PRINCIPAL INVESTIGATOR/PROJECT MANAGER: (Name, E-mail, Mail Address, City/State/ZIP, Phone)
Valery Temyanko
vtemyanko@optics.arizona.edu
1430 North 6th Avenue
Tucson,  AZ 85705-6644
(520) 622-0804

Estimated Technology Readiness Level (TRL) at beginning and end of contract:
Begin: 3
End: 4

TECHNICAL ABSTRACT (LIMIT 200 WORDS)
Deep-ultraviolet (DUV) Raman spectroscopy is a powerful method to isolate and extract the unique signatures of numerous chemical bonds present within complex samples. DUV (&#955; < 250 nm) excitation is critical for NASA missions because it shows an over 200-fold greater efficiency compared to commonly used 785 nm excitation and illumination as such short wavelengths minimizes the fluorescence background in the Raman spectra. The unavailability of compact, robust, and reliable deep-UV laser sources has constrained implementing DUV Raman spectroscopy in NASA's space-borne exploration and research. TIPD proposes to develop an ultrastable, compact, and robust DUV laser source for Raman spectroscopy based on our demonstrated capability in developing single-frequency fiber lasers and solid-state DUV laser sources. Cooperating with the University of Arizona, TIPD developed an ultrastable and compact single-frequency linearly polarized fiber laser system operating at 976 nm during the Phase I program. The team also developed a single-frequency fiber amplifier at 976 nm and single-pass frequency doubling of 976 nm light to demonstrate the viability of the compact design. Separately, the team has designed and delivered a 150 mW DUV laser for Raman spectroscopy operating at 244 nm using a BBO crystal and a resonant bow-tie cavity based upon a 976 nm VECSEL source. In phase II, the team will scale the power of the 976 nm fiber amplifier to achieve a 5-watt single-frequency output. The 5-watt single-frequency 976nm master oscillator power amplifier (MOPA) will act as the pump to build a 100-mW deep-UV laser prototype that will be delivered to NASA.

POTENTIAL NASA COMMERCIAL APPLICATION(S) (LIMIT 150 WORDS)
Deep UV sources can be broadly used for Raman spectroscopy, laser cooling and trapping, laser inspection, optical data storage, metrology, biomedical applications, and laser lithography. The ultra-stable, high power, narrow-linewidth 976nm laser has applications beyond this program including laser sources for nonlinear wavelength conversion, and as a low noise laser pumps for a variety of lasers at 1 ??m and 1.5 ??m. The 488 nm blue laser, which is part of 244 nm system, has potential applications in submarine imaging, sensing, communications, data storage, undersea oil exploration, full color displays, and medicine.

POTENTIAL NON-NASA APPLICATION(S) (LIMIT 150 WORDS)
Deep-UV Raman spectroscopy is a powerful tool to identify a variety of gas, liquid, and solid materials critical to understanding the evolution of the solar system and the universe. Compact and ultrastable DUV laser sources can be used for analysis of geological and mineralogical planetary composition, planetary habitability assessment, and for the search of past life on Mars, and for human protection in space.

TECHNOLOGY TAXONOMY MAPPING
Lasers (Measuring/Sensing)

SMALL BUSINESS CONCERN: (Firm Name, Mail Address, City/State/ZIP, Phone)
Nanosonic, Inc.
158 Wheatland Drive
Pembroke, VA 24136-3645
(540) 626-6266

RESEARCH INSTITUTION: (RI Name, Mail Address, City/State/ZIP, Phone)
Colorado State University
Sponsored Programs
Fort Collins, CO 80523-2002
(970) 491-1541

PRINCIPAL INVESTIGATOR/PROJECT MANAGER: (Name, E-mail, Mail Address, City/State/ZIP, Phone)
Jennifer Lalli
jhlalli@nanosonic.com
158 Wheatland Drive
Pembroke,  VA 24136-3645
(540) 626-6266

Estimated Technology Readiness Level (TRL) at beginning and end of contract:
Begin: 5
End: 7

TECHNICAL ABSTRACT (LIMIT 200 WORDS)
NanoSonic has developed revolutionary multifunctional, super lightweight, self-healing and radiation shielding carbon fiber reinforced polymer (CFRP) composites as a viable lightweight material for space applications such as primary or secondary structures on NASA vehicles, habitat modules, and pressure vessel structures. While current composites are lightweight, they do not offer reliable methods for damage inspection. These advanced materials offer the ability to self-heal upon impact and allow for micro crack damage inspection via DC or RF measurements. During the Phase I program, this phenomenon was demonstrated on multifunctional smart structural composites consisting of: carbon fiber plies, NanoSonic's Thoraeus Rubber&#153; Kevlar Lightweight Shieling Veils (LSV), and our conductive self-healing microcapsules. The innovative microcapsules are comprised of a corrosion resistant HybridShield polymer shell, a resin-rich core of self-repairing, room temperature curing polymer, and Al nanoparticles to impart EMI and radiation shielding as well as a conductive pathway between the conductive Thoraeus Rubber veils to monitor both damage and repair via RF measurements. NanoSonic is working with Colorado State University, ILC Dover, and Lockheed Martin Space Systems Company to increase the TRL of this technology from 5-7 during the Phase II program via mechanical, RF, and radiation shielding measurements and space qualification testing.

POTENTIAL NASA COMMERCIAL APPLICATION(S) (LIMIT 150 WORDS)
Non-NASA applications for the self-healing composites include long-term protective storage liners for food or other sensitive materials, self-sealing tires, anti-ballistic fuel tanks and life critical personnel protective equipment (PPE). The EMI and radiation shielding protective constituent offer utility as cost effective protection against electrostatic charging, radiation, and abrasion. Aerospace, biomedical and microelectronic markets would benefit from the EMI SE under repeated and severe reconfigurations. Such EMI shielding skins can be envisioned for use on aircraft, morphing unmanned aerial vehicles, antennas and space structures. Structural, high temperature, composite materials having unique dielectric and multiple controlled electromagnetic properties are possible via NanoSonic's layer-by-layer approach. Spray ESA is envisioned as a cost-effective, environmentally friendly technology to displace sputtering and traditional dense filled composites. Metal Rubber&#153; fabrics and films can also function as conducting electrodes for high strain mechanical actuator and sensor devices, or as electrically conductive mechanically flexible ground planes or electrical interconnection.

POTENTIAL NON-NASA APPLICATION(S) (LIMIT 150 WORDS)
NanoSonic's HybridShield Metal Rubber (HS-MR) materials will be primarily transitioned as smart, lightweight, multifunctional, self-healing composites for spacecraft to further NASA Space Exploration Program. The materials shall be engineered for both primary and secondary structures, including vehicle, habitat module, and pressure vessel structures. The multifunctional MR nano-additive component of the self-healing materials formed via NanoSonic's ESA process offer EMI and radiation shielding for enhanced long-term high altitude and space durability. Such higher specific strength self-healing composites will result in drastic reductions in uptake mass and increased reliability for more cost effective and efficient space exploration. Specifically, the composites shall monitor the extent of damage and repair such destruction throughout the lifecycle from manufacturing, to a tool drop, and in service due to micrometeoroid and orbital debris impacts on orbit. Both coupons and a targeted space demonstrator shall be produced during this program with our space partners.

TECHNOLOGY TAXONOMY MAPPING
Airship/Lighter-than-Air Craft
Spacecraft Design, Construction, Testing, & Performance (see also Engineering; Testing & Evaluation)
Protective Clothing/Space Suits/Breathing Apparatus
Outreach
In Situ Manufacturing
Coatings/Surface Treatments
Composites
Nanomaterials
Polymers
Smart/Multifunctional Materials

SMALL BUSINESS CONCERN: (Firm Name, Mail Address, City/State/ZIP, Phone)
Aurora Flight Sciences Corporation
90 Broadway 11th Floor
Cambridge, MA 02142-1050
(703) 369-3633

RESEARCH INSTITUTION: (RI Name, Mail Address, City/State/ZIP, Phone)
University of Massachusetts - Lowell
600 Suffolk Street Room 226
Lowell, MA 01854-3643
(978) 934-4723

PRINCIPAL INVESTIGATOR/PROJECT MANAGER: (Name, E-mail, Mail Address, City/State/ZIP, Phone)
Konstantine Fetfatsidis
kfetfatsidis@aurora.aero
90 Broadway, 11th Floor
Cambridge,  MA 02142-1050
(617) 229-6818

Estimated Technology Readiness Level (TRL) at beginning and end of contract:
Begin: 4
End: 5

TECHNICAL ABSTRACT (LIMIT 200 WORDS)
After successfully demonstrating the basic functionality of a damage-detecting, self-healing 'smart' material system in Phase I, Aurora and UMass Lowell aim to advance the material technology to a TRL 5 in Phase II. The team will use their 'smart' material system to design and manufacture various scaled-up core-stiffened composite specimens in application-appropriate geometries, and subsequently test the specimens in a simulated operational environment that includes hypervelocity impact to simulate MMOD impacts, and thermal cycling to represent the large temperature gradients in space. Aurora and UMass Lowell will automate the resistive heating process by relying on changes in the flow of heat through the material as measured by sending electrical current through the structure and monitoring using infrared thermography. Based on the extent of damage, additional heat can be automatically triggered to accelerate healing. The team will consider the integration of the 'smart' material into a larger system in Phase II, including the storage of fluid within the honeycomb core cells to re-fill micro-channels. Vertically aligned carbon nanotubes (VACNTs) from N12 Technologies, Inc. will be continuously transfer-printed onto the carbon fiber prepreg slit tape and spooled for automated fiber placement (AFP). When laid down by AFP, the VACNTs will "stitch" adjacent layers together to reinforce the interlaminar region and improve the damage tolerance of the overall structure with a negligible increase in weight and thickness. At the end of Phase II, the team will work with NASA Langley Research Center's new Integrated Structural Assembly of Advanced Composites facility to manufacture a scaled pressure vessel that will be damaged via hypervelocity impact multiple times to evaluate its self-healing performance. This scaled demonstration will enable the team to define further scale-up requirements and make cost and performance predictions for subsequent development phases.

POTENTIAL NASA COMMERCIAL APPLICATION(S) (LIMIT 150 WORDS)
As an aerospace company, Aurora designs, develops, and manufactures various primary and secondary composite structures for unmanned and manned, military and commercial aircraft. The structures, over repeated load cycles, will develop cracks that affect performance and require significant downtime and maintenance. Being able to integrate damage detection and self-healing capabilities with these structures will position Aurora to offer innovative new, "smarter" designs for commercial customers, that are more lightweight and damage tolerant. Aurora is already working on an application that detects damage and dynamically adjusts its flight parameters (e.g. lower altitude, different speed, etc.) to maximize performance prior to grounding for repairs. A self-healing system would enable the aircraft to fly for a longer period of time and complete its required mission without unnecessarily grounding the aircraft for maintenance and repairs. Furthermore, Aurora could leverage its relationship with major prepreggers such as Cytec, Hexcel, TenCate, and Toray to license the "smart" material out for subsequent sales to other industries including wind energy, automotive, and construction (e.g. buildings and bridges).

POTENTIAL NON-NASA APPLICATION(S) (LIMIT 150 WORDS)
The developed "smart" material has several applications within NASA. First, the smart aspects are integrated with a commercially available OOA prepreg material suitable for large, lightweight composite structures. Second, this material is compatible with AFP for cost-effective, rapid manufacture of such large, lightweight structures. Furthermore, the implementation of the smart aspects is done using automated, controlled processes. The microvascular channels for self-healing are fabricated using a FDM print-head that can be interfaced with the AFP machine, while the CNTs are transferred continuously to prepreg slit tape and spooled prior to AFP. This combination of materials and manufacturing processes lends itself attractive for applications within NASA's Space Exploration program such as large pressure vessels, vehicles, and habitat modules. The lifetime and reliability of these structures will be improved as they become larger and lighter weight, and are sent deeper into space for future missions. Clearly, after these structures are launched into space, it is often not practical to service them in the event of any damage. The ability to detect damage and to self-heal will be advantageous in such cases. With the success of this STTR program, Aurora will have positioned itself to compete for future NASA contracts that require the manufacture of large, composite space structures similar to the Orion heavy lift launch vehicle, the SLS, and NASA's COTS vehicle.

TECHNOLOGY TAXONOMY MAPPING
Recovery (see also Vehicle Health Management)
Thermal Imaging (see also Testing & Evaluation)
Processing Methods
Composites
Nanomaterials
Polymers
Smart/Multifunctional Materials
Pressure & Vacuum Systems
Structures

SMALL BUSINESS CONCERN: (Firm Name, Mail Address, City/State/ZIP, Phone)
ProtoInnovations, LLC
5453 Albemarle Avenue
Pittsburgh, PA 15217-1132
(412) 916-8807

RESEARCH INSTITUTION: (RI Name, Mail Address, City/State/ZIP, Phone)
Massachusetts Institute of Technology
77 Massachusetts Avenue
Cambridge, MA 02139-4301
(617) 252-1490

PRINCIPAL INVESTIGATOR/PROJECT MANAGER: (Name, E-mail, Mail Address, City/State/ZIP, Phone)
KARL IAGNEMMA
kdi@mit.edu
77 Massachusetts Avenue
Cambridge,  MA 02139-4301
(617) 452-3262

Estimated Technology Readiness Level (TRL) at beginning and end of contract:
Begin: 3
End: 6

TECHNICAL ABSTRACT (LIMIT 200 WORDS)
ProtoInnovations, LLC (PI) and the Massachusetts Institute of Technology (MIT) have formed a partnership to research, develop, and experimentally characterize a suite of robotic controls to significantly improve the safety, mean travel speed, and rough-terrain access of wheeled planetary rovers. In meeting this goal we have been developing algorithms for all-terrain adaptive locomotion which include: 1. Advanced traction controls, which intelligently govern individual wheel commands as a function of terrain conditions in order to measurably decrease wheel slip; and, 2. Real-time incipient embedding detection controls, which monitors the rover's inertial signature to rapidly and robustly detect instances of incipient embedding in soft, low bearing-strength soils. The implementation of these controls will not only allow rovers to autonomously detect and avoid hazardous terrain regions, but also to travel with assured safety on terrain that is steeper and rougher than is currently possible. Moreover, these controls will allow rovers to drive with a reduced risk of catastrophic failure, while simultaneously increasing both the quantity and potential quality of science data products. This latter capability is enabled by the fact that rovers will be able to travel for long durations without requiring lengthy human interventions, and will be able to travel to sites of greater scientific interest (and proportionally greater mobility difficulty) than what is possible today.

POTENTIAL NASA COMMERCIAL APPLICATION(S) (LIMIT 150 WORDS)
Beyond NASA, there is a large and growing application space for mobile robotic systems in applications such as defense and security, mining and forestry, and infrastructure monitoring and inspection. Many of these systems are tasked with traveling at low speeds through very difficult terrain. The PI/MIT team will aim to transition the technology developed under this project beyond NASA, to dual-use applications in these various sectors.

POTENTIAL NON-NASA APPLICATION(S) (LIMIT 150 WORDS)
The proposed research is expected to greatly enhance the mobility and tractive performance of robotic planetary rovers. In Phase 2 we will demonstrate our advanced traction control methods to various individuals at NASA centers, with the aim of identifying potential future missions for transition of this technology. The 2020 Mars rover mission is an example of such mission that could directly benefit from the algorithms and control methods developed under this STTR project. The PI/MIT team will actively seek post-Phase 2 support to further develop, mature, and integrate our control technology into future NASA missions.

TECHNOLOGY TAXONOMY MAPPING
Autonomous Control (see also Control & Monitoring)
Intelligence
Recovery (see also Vehicle Health Management)
Robotics (see also Control & Monitoring; Sensors)
Algorithms/Control Software & Systems (see also Autonomous Systems)
Command & Control
Diagnostics/Prognostics

SMALL BUSINESS CONCERN: (Firm Name, Mail Address, City/State/ZIP, Phone)
ATA Engineering, Inc.
13290 Evening Creek Drive South, Suite 250
San Diego, CA 92128-4695
(858) 480-2000

RESEARCH INSTITUTION: (RI Name, Mail Address, City/State/ZIP, Phone)
University of Mississippi
P.O. Box 1848
University, MS 38677-1848
(662) 915-7482

PRINCIPAL INVESTIGATOR/PROJECT MANAGER: (Name, E-mail, Mail Address, City/State/ZIP, Phone)
Michael Yang
myang@ata-e.com
13290 Evening Creek Drive, Suite 250
San Diego,  CA 92128-4424
(858) 480-2040

Estimated Technology Readiness Level (TRL) at beginning and end of contract:
Begin: 3
End: 6

TECHNICAL ABSTRACT (LIMIT 200 WORDS)
ATA Engineering, Inc. proposes an STTR program to develop innovative tools and methods that will significantly improve the accuracy of random vibration response predictions for aerospace structures under critical inhomogeneous aeroacoustic loads. This will allow more accurate predictions of structural responses to be made, potentially reducing vehicle weight and cost and improving the reliability of these structures. Empirical wind tunnel test data will be used as a basis to develop novel methods to characterize the surface fluctuating pressures encountered by launch vehicles during ascent, and then to accurately predict the random vibration environment caused by these loads. In Phase II, we will perform a wind tunnel test campaign at the University of Mississippi to measure both the surface fluctuating pressure and the resulting vibration in a flexible panel positioned on an expansion corner. The data from these tests will be used to develop more accurate models to predict the auto- and cross-spectra of surface fluctuating pressures during ascent, followed by the development of coupling models to predict the resulting spacecraft structural vibrations. A critical improvement over current methods will be the inclusion of a statistical basis which will enable prediction of both mean and maximum expected environments. The experimental data in Phase II can also be used as a source of validation for unsteady coupled fluid-structural dynamics simulations.

POTENTIAL NASA COMMERCIAL APPLICATION(S) (LIMIT 150 WORDS)
As the aerospace industry adapts to the retirement of the Space Shuttle, it stands poised at the beginning of a new era of space exploration and commercial space activities. Numerous private sector companies are developing the next generation of commercial launch vehicles, space station resupply services, and spacecraft for the suborbital space tourism market. A common theme for these new systems is that they feature innovative designs that make a marked departure from the legacy spaceflight and rocket systems employed in the last half decade of orbital launches. New concepts such as Virgin Galactic's SpaceShip Two spaceplane and SpaceX's nine-engine Falcon 9 rocket provide a host of new vibroacoustic scenarios that must be understood and addressed as part of certifying payload survivability or human passenger safety. By enabling more accurate prediction of the vibroacoustic response of these systems, the methods developed in this project will contribute to the design of more efficient and reliable systems while reducing the mission risk from unaccounted aeroacoustic loads. ATA will make this technology available to industry by offering engineering consulting services and specialized software.

POTENTIAL NON-NASA APPLICATION(S) (LIMIT 150 WORDS)
The methods and embodying software that will be developed under this project will provide unprecedented accuracy in predicting aeroacoustic loading and vibration response for any spacecraft or launch vehicle during ascent. One of the most noteworthy and immediate opportunities for infusion of this technology is in the design of NASA's Space Launch System (SLS), an advanced heavy-lift launch vehicle being developed. The SLS will deliver the Orion Multi-Purpose Crew Vehicle to space and will be involved in a number of commercial and International Space Station missions. The technologies proposed do not carry much risk and provide an opportunity early in the development process to make design decisions that can result in significant increases in affordability, reliability, and performance. Additionally, the design of systems and components aboard more near-term NASA spaceflight missions will benefit from the improved predictive capability, with specific examples including the proposed series of Commercial Crew and Cargo Program (C3PO) launches and prospective extraterrestrial missions such as Mars 2020. The proposed technology directly addresses the high-priority challenge for "analytical capabilities that go far beyond existing modeling and simulation capabilities and reduce use of empirical approaches in vehicle design" identified in NASA's Space Technology Roadmap for Technology Area 11: Modeling, Simulation, Information Technology, & Processing.

TECHNOLOGY TAXONOMY MAPPING
Aerodynamics
Spacecraft Design, Construction, Testing, & Performance (see also Engineering; Testing & Evaluation)
Space Transportation & Safety
Models & Simulations (see also Testing & Evaluation)
Structures
Launch Engine/Booster

SMALL BUSINESS CONCERN: (Firm Name, Mail Address, City/State/ZIP, Phone)
Physical Sciences, Inc.
20 New England Business Center
Andover, MA 01810-1077
(978) 689-0003

RESEARCH INSTITUTION: (RI Name, Mail Address, City/State/ZIP, Phone)
University of California, Santa Barbara
342 Lagoon Road
Santa Barbara, CA 93106-2055
(805) 893-5197

PRINCIPAL INVESTIGATOR/PROJECT MANAGER: (Name, E-mail, Mail Address, City/State/ZIP, Phone)
Frederick Lauten
lauten@psicorp.com
20 New England Business Center
Andover,  MA 01810-1077
(978) 738-8277

Estimated Technology Readiness Level (TRL) at beginning and end of contract:
Begin: 2
End: 5

TECHNICAL ABSTRACT (LIMIT 200 WORDS)
Silicon Carbide based ceramic matrix composites (CMCs) offer the potential to fundamentally change the design and manufacture of aeronautical and space propulsion systems to significantly increase performance and fuel efficiency over current metal-based designs. Physical Sciences Inc. (PSI) and our team members at the University of California Santa Barbara (UCSB) are developing, designing and fabricating enhanced SiC-based matrices capable of long term operation at 2750oF to 3000oF in the combustion environment. Our approach is successfully building upon PSI's and UCSB's previous work in incorporating refractory and rare earth species into the SiC matrix to increase the CMC use temperatures and life-time capabilities by improving the protective oxide passivation layer that forms during use. As part of this work we are creating physics based-materials and process models that qualitatively define methods of improving matrix properties and the interaction of the fibers, interphases and matrix with each other. In the Phase I program the PSI team developed and experimentally demonstrated CMC's capable of withstanding 100's of hours of oxidation at 2700oF with no degradation. We have focused predicting the effect of phase distribution, grain size, chemical composition, matrix density, and surface flaws on the oxidation behavior of the CMC matrix. During the Phase II program we will iteratively improve the CMC performance by optimizing the composition and characteristics of the additives based on oxidation and mechanical test results and burner rig exposure testing.

POTENTIAL NASA COMMERCIAL APPLICATION(S) (LIMIT 150 WORDS)
Commercial aircraft engines, both large and small, will benefit from low-cost, technically superior CMCs that enable higher temperature operation of CMC-based components. In addition, CMCs are currently being tested in ground-based gas turbines for power generation, where long-life high temperature survival is of particular importance.

POTENTIAL NON-NASA APPLICATION(S) (LIMIT 150 WORDS)
High temperature stabilized SiC-based matrices will enable operation of SiCf/SiC ceramic composites (CMCs) at temperatures well above 2700?F. Use of CMC-based components such as combustor liners, turbine shrouds, and turbine vanes will enable higher temperature operation of turbine engines in subsonic, supersonic, and hypersonic aircraft. The lighter weight of the CMC components will reduce fuel consumption and their higher temperature operation will reduce air cooling requirements, decrease NOx emissions, and improve overall engine efficiency. These factors will result in significantly reduced costs for aircraft engine operation and the increase in performance afforded by CMCs will be an enabling factor for Low-Cost and Reliable Access to Space (LCRATS).

TECHNOLOGY TAXONOMY MAPPING
Characterization
Models & Simulations (see also Testing & Evaluation)
Prototyping
Processing Methods
Ceramics
Coatings/Surface Treatments
Composites
Atmospheric Propulsion

SMALL BUSINESS CONCERN: (Firm Name, Mail Address, City/State/ZIP, Phone)
Elder Research, Inc.
300 West Main Street, Suite 301
CHARLOTTESVILLE, VA 22903-5575
(434) 973-7673

RESEARCH INSTITUTION: (RI Name, Mail Address, City/State/ZIP, Phone)
Southwest Research Institute
6220 Culebra Road
San Antonio, TX 78238-5166
(210) 522-2081

PRINCIPAL INVESTIGATOR/PROJECT MANAGER: (Name, E-mail, Mail Address, City/State/ZIP, Phone)
Simeon Fitch
fitch@datamininglab.com
300 W MAIN ST STE 301
CHARLOTTESVILLE,  VA 22903-5575
(434) 973-7673

Estimated Technology Readiness Level (TRL) at beginning and end of contract:
Begin: 2
End: 3

TECHNICAL ABSTRACT (LIMIT 200 WORDS)
The technical objectives of this program are: (1) to develop a set of physics-based modeling tools to predict the initiation of hot corrosion and to address pit and fatigue crack formation in Ni-based alloys subjected to corrosive environments, (2) to implement this set of physics-based modeling tools into the DARWIN probabilistic life-prediction code, and (3) to demonstrate corrosion fatigue crack initiation and growth life prediction for turbine disks subjected to low-cycle and high-cycle fatigue loading in extreme environments. This technology will significantly improve the current ability to simulate and avoid corrosion fatigue failure of engine disks or metallic structural components due to prolonged exposure to extreme environments at elevated temperatures. Completion of the proposed program will provide probabilistic corrosion fatigue crack growth life assessment software tools for structural components subjected to aggressive hot corrosion environments. Such a suite of software tools is unique and is urgently needed for designing and improving the performance of critical structures used in the space structure and propulsion systems in commercial and military gas turbine engines, and oil and gas industries. This generic technology can also be used to provide guidance for developing new alloys or improving current Ni-based alloy designs for hot-section applications.

POTENTIAL NASA COMMERCIAL APPLICATION(S) (LIMIT 150 WORDS)
In Phase III, ERI will work with SwRI and the OEM team member(s) to commercialize the hot corrosion prediction software package either as parts or a stand-alone software tool for designing, lifing and risk assessment of structural components subjected to hot corrosion environment. Such a suite of software tools is unique and is urgently needed for designing and improving the performance of critical structures used in extreme environments. We see a potential market for such a software tool both in the military gas turbine engine sector, industrial gas turbine engine sector, oil and gas industries, and nuclear power industries. The software packages can be used to develop new Ni-based alloys or improve current Ni-based alloys for services in extreme environments and to provide accurate life prediction and reliability assessment of Ni-based superalloy components used in hot corrosion environments.

POTENTIAL NON-NASA APPLICATION(S) (LIMIT 150 WORDS)
In Phase III, ERI will work with SwRI and the OEM team member(s) to commercialize the hot corrosion prediction software package either as parts or a stand-alone software tool for designing, lifing and risk assessment of structural components subjected to hot corrosion environments. Such a suite of software tools is unique and is urgently needed for designing and improving the performance of critical structures used in extreme environments. We see a potential market for such a software tool both in the commercial aerospace gas turbine engine sector and in the space structure, rocket and propulsion sectors. The software packages can be used to develop new Ni-based alloys or improve current Ni-based alloys for services in extreme corrosive atmospheres such as in Venus. In addition, the software package can be utilized to provide accurate life prediction and reliability assessment of Ni-based superalloy components used in hot corrosion environments.

TECHNOLOGY TAXONOMY MAPPING
Quality/Reliability
Software Tools (Analysis, Design)
Processing Methods
Coatings/Surface Treatments
Composites
Metallics
Atmospheric Propulsion
Lifetime Testing
Nondestructive Evaluation (NDE; NDT)
Simulation & Modeling

SMALL BUSINESS CONCERN: (Firm Name, Mail Address, City/State/ZIP, Phone)
Applied Optimization, Inc.
714 East Monument Avenue, Suite 204
Dayton, OH 45402-1382
(937) 431-5100

RESEARCH INSTITUTION: (RI Name, Mail Address, City/State/ZIP, Phone)
University of Tennessee Knoxville
1534 White Avenue, Blount Hall
Knoxville, TN 37996-1529
(865) 974-3466

PRINCIPAL INVESTIGATOR/PROJECT MANAGER: (Name, E-mail, Mail Address, City/State/ZIP, Phone)
Anil Chaudhary
anil@appliedo.com
714 E. Monument Ave., Ste. 204
Dayton,  OH 45402-1382
(937) 431-5100

Estimated Technology Readiness Level (TRL) at beginning and end of contract:
Begin: 4
End: 5

TECHNICAL ABSTRACT (LIMIT 200 WORDS)
The ability to assign a level of confidence for build quality is fundamental to the deployment of powder bed technology. Accordingly, the research objective of this work is to use probability theory as a glue to combine the physics-based models used for the selection of processing parameters together in order to produce quality deposits using the following approach: (1) Use probability theory as the glue to combine physics-based models for melt-pool thermal-fluid behavior and track cross-section formation in order to determine the deposition parameters; (2) Enhance the physics-based model to predict vaporization and expulsion of the additive material, melt pool buckling, transport of gas bubbles, determination of hatch distance, inter-track and inter-layer wetting; (3) Perform probabilistic assessment for the performance of the deposition parameters for their ability to mitigate defects, attain consistency of size for the fused tracks, flatness of the top layer, and the material microstructure; (4) Use the solidification parameters and thermal cycling during deposition to predict the precipitation reactions; (5) Perform deposition experiments to demonstrate the ability to engineer the deposition parameters. This work would result in reduction of effort for the development of process parameters and part qualification for specialty materials of interest to NASA.

POTENTIAL NASA COMMERCIAL APPLICATION(S) (LIMIT 150 WORDS)
Physics-based selection of SLM and EBM process parameters to mitigate defects and to control microstructure for materials utilized in the land or sea-based gas-turbine engines, for life-extension of aging systems, etc.

POTENTIAL NON-NASA APPLICATION(S) (LIMIT 150 WORDS)
The NASA application is to enable physics-based selection of SLM and EBM process parameters, while taking into account the statistics of substrate roughness, scanning direction and track formation. It is designed to reduce the effort needed to meet certification requirements for NASA parts. This application is needed because the current use of SLM and EBM uses process parameters that are developed on the basis of experimental trial and error; and these parameters are available for only a few alloys. This work is expected to reduce effort for the selection of process parameter for new alloys by up to a factor of two to four.

TECHNOLOGY TAXONOMY MAPPING
Analytical Methods
Models & Simulations (see also Testing & Evaluation)
Processing Methods
Metallics
Smart/Multifunctional Materials
Simulation & Modeling

SMALL BUSINESS CONCERN: (Firm Name, Mail Address, City/State/ZIP, Phone)
Mound Laser & Photonics Center, Inc.
2941 College Drive
Kettering, OH 45420-1172
(937) 865-3730

RESEARCH INSTITUTION: (RI Name, Mail Address, City/State/ZIP, Phone)
Wright State University
3640 Colonel Glenn Highway
Dayton, OH 45435-0001
(937) 775-2425

PRINCIPAL INVESTIGATOR/PROJECT MANAGER: (Name, E-mail, Mail Address, City/State/ZIP, Phone)
John Middendorf
johnmiddendorf@mlpc.com
2941 College Drive
Kettering,  OH 45420-1172
(937) 865-3492

Estimated Technology Readiness Level (TRL) at beginning and end of contract:
Begin: 3
End: 5

TECHNICAL ABSTRACT (LIMIT 200 WORDS)
In Phase I of this project MLPC, WSU, and AFIT were successfully able to identify several optical data features that are indicative of the quality of components built with the selective laser melting additive manufacturing process. Four unique optical sensors were identified to collect this information and they include infrared and visible wavelength high-speed cameras and spectrometers. The sensors used in Phase I were very expensive, university developed, and produce very big data sets. In this phase II proposal MLPC and their collaborators will continue this work by developing a new low-cost sensor system to specifically track key data features identified in Phase I. This sensor system will then be used to perform in-process quality monitoring and qualification of manufactured parts. In Phase II this analysis will also be extended to electron beam freeform fabrication. To complete the project MLPC, WSU, and AFIT will continue analysis of the Phase I sensor data to identify more obscure process quality data, and develop process maps that correlate sensor output to part microstructure. Then MLPC and AFIT will design and build the low-cost sensor system to track all key data, and test it on MLPCs custom build additive manufacturing test cell. Next MLPC will perform the necessary programming and data processing to implement a process monitoring system that will show sensor data position on the process maps in real-time, thus enabling in-process quality assurance. MLPC will then study and report the cost savings NASA could gain with this technology. Finally, MLPC will test this concept on an electron beam system and determine its viability for that process. At the end of Phase II the TRL will be 5, and this product will be ready for licensing for commercial use in existing additive manufacturing machines, and the MLPC developed additive manufacturing system will be available for licensing as a package unit with the integrated sensor system.

POTENTIAL NASA COMMERCIAL APPLICATION(S) (LIMIT 150 WORDS)
The aerospace commercial applications have strong overlap with NASA applications, including strong interest in fabrication of rocket engine components and a variety of other lightweighted structures. There are three aspects of the sensor technology of particular interest to commercial market: 1) implementation of process observation and build metrics quantification that is not currently available in commercial laser additive manufacturing machines; 2) guidance of more rapid additive manufacturing process developement; 3) exploitation of the in situ process monitoring to provide feedback that would enable closed-loop process control. The Army (via ARDEC) has also expressed interest in the sensor technology. Finally, the small business on this STTR has an interest in using the STTR sensor technology to help develop miniature additive manufacturing techniques to make components for the medical device industry.

POTENTIAL NON-NASA APPLICATION(S) (LIMIT 150 WORDS)
The sensor technology and analysis and control protocols developed under this STTR project will allow improved process control and verification for additive manufacturing (AM) conducted by selective laser melting (SLM) and by e-beam processing. The technology as applied to SLM supports the goals of the AM lab at Marshall Space Flight Center and the Materials Genome Initiative of the NASA Space Technology Mission Directorate. The technology as applied to e-beam supports the goals of electron beam freeform fabrication (EBF3) developed at Langley Research Center. Implementation of the technology can improve or enable the manufacture of all parts envisioned to be made by these methods. This impacts a number of space platforms and terrestrial applications that is too large to list. Of particular value to NASA will be the technologies ability to provide a high degree of in-process monitoring to verify build quality. Documentation of actual build conditions can be generated that will constitute a key aspect of non-destructive evaluation (NDE) data, improving confidence levels for additively manufactured parts and allowing them to qualify for transition into NASA flight missions. NASA also has an interest in using the in situ process data to inform and verify modeling of additive manufacturing processes.

TECHNOLOGY TAXONOMY MAPPING
Process Monitoring & Control
Prototyping
Quality/Reliability
In Situ Manufacturing
Processing Methods
Metallics
Visible
Infrared
Multispectral/Hyperspectral
Nondestructive Evaluation (NDE; NDT)

SMALL BUSINESS CONCERN: (Firm Name, Mail Address, City/State/ZIP, Phone)
CFD Research Corporation
701 McMillian Way NW, Suite D
Huntsville, AL 35806-2923
(256) 726-4800

RESEARCH INSTITUTION: (RI Name, Mail Address, City/State/ZIP, Phone)
University of Alabama
152 Rose Administration Building
Tuscaloosa, AL 35487-0104
(205) 348-5152

PRINCIPAL INVESTIGATOR/PROJECT MANAGER: (Name, E-mail, Mail Address, City/State/ZIP, Phone)
J. Cole
jvc@cfdrc.com
701 McMillian Way, NW, Ste D
Huntsville,  AL 35806-2923
(256) 726-4800

Estimated Technology Readiness Level (TRL) at beginning and end of contract:
Begin: 2
End: 3

TECHNICAL ABSTRACT (LIMIT 200 WORDS)
Despite the rapid commercialization of additive manufacturing technology such as selective laser melting, SLM, there are gaps in process modeling and material property prediction that contribute to slow and costly process development, process qualification and product certification. To address these gaps, CFDRC and our partner Dr. Kevin Chou, University of Alabama, will develop multiple computationally efficient, high-fidelity simulation tools for the SLM process. During Phase I the team demonstrated efficient thermomechanical simulations for centimeter size test coupon builds, the feasibility of applying multiphase flow models to analyze particle scale effects on material variations, application of phase field models to predict microstructure evolution, and experimental characterization for model verification and refinement. During Phase II, the modeling tools will be extended to improve computational efficiency and scalability to aerospace component dimensions by further leveraging parallel computing and other acceleration techniques. The fidelity of the models will be enhanced to better predict distortion, residual stress, microstructure and defects from process conditions; and additional process data will be used to validate the resulting codes. The high-fidelity, physics based nature of the codes will allow straightforward application to new materials, and to guiding development of and verifying analytical physics models for process control.

POTENTIAL NASA COMMERCIAL APPLICATION(S) (LIMIT 150 WORDS)
Mature AM technologies will benefit designers and producers of aerospace components for military and civilian aircraft with low 'buy-to-fly' costs and increased functionality similar to the NASA benefits. Beyond the aerospace industry, there are opportunities for this technology in other high-value engineering applications such as production of patient-specific biocompatible implants.

POTENTIAL NON-NASA APPLICATION(S) (LIMIT 150 WORDS)
NASA has demonstrated the potential for cost and time savings via additive manufacturing, successfully building and testing a complex rocket injector. The build took 3 weeks, at half the cost of traditional methods that require 6 months. The technology also offers the potential for design flexibility, weight savings, and increased reliability from monolithic parts with reduced joining. The proposed models will allow for a deeper understanding of the resulting material properties and increase the confidence in, and use of, additive manufactured parts. Furthermore the tools will enable process control and reduced time to optimize the recipe for a given part, thereby enabling the proliferation of additive manufacturing as a rapid prototyping and production tool for components in critical NASA systems.

TECHNOLOGY TAXONOMY MAPPING
Models & Simulations (see also Testing & Evaluation)
Prototyping
Quality/Reliability
Software Tools (Analysis, Design)
Metallics
Lasers (Machining/Materials Processing)