{"project":{"acronym":"","projectId":90324,"title":"Advanced Composite Truss (ACT) Printing for Large Solar Array Structures","startTrl":3,"currentTrl":6,"endTrl":6,"benefits":"The primary market for the ACT additive manufacturing technology is large (100 kW-1 MW) solar arrays. However, the ACT system is reconfigurable, scalable, and reprogrammable, making it applicable to a large number of other space applications. The ACT system could also be implemented for structural reinforcement for the ISS or other space structures, structural booms for solar arrays on lightweight space structures, Mars colonization infrastructure, straight and curved primary structure on satellites or future space stations. SDC estimates that the ROI for launching the ACT system on five (5) different missions will exceed 3. The ACT system has direct applicability to the asteroid redirect mission, the Mars Exploration missions, and NASA commercial resupply missions.
The ACT system is being developed with complete printer and structure tailorability to meet a range of mission objectives. Additional applications include private space exploration spacecraft that employ solar electric propulsion, private space stations, and terrestrial applications including low wind resistant booms, light weight antenna structures, and tether satellite structures (electrodynamic and moment tethers). SDC estimates that if the ACT system could be utilized in a production environment (either in space or on earth), ROIs of 10-100 could be realized.","description":"Large solar arrays (100 kW-1 MW) are required in order to generate the power necessary for solar electric propulsion to drive NASA's future missions, including: Asteroid Redirect Mission, Mars Exploration, and NASA Commercial Supply. The advantages and benefits of large solar array designs will only be realized if the array support structure weight and packaging volume are minimized. SDC's Advanced Composite Truss (ACT) additive manufacturing technology can provide a 30-40% weight savings and a 250-300% improvement in power per unit volume over existing state-of- the-art solar array boom structures. The ACT technology consists of the lightweight advanced composite truss, the autonomous low-packing volume ACT printer, and an integrated solar array deployment system. The weight of the ACT structure is designed to optimize the load carrying path within an open truss architecture. The material for the truss is efficiently packaged within the envelope of the ACT printer prior to launch. Once in orbit, the ACT printer autonomously manufactures the ACT structure without the need for mechanical joints. The ACT printer can be scaled to manufacture any size, length, and/or geometry truss required to meet the prescribed mission requirements. Following the manufacture of the ACT truss, the integrated drive system of the ACT printer autonomously deploys the solar array.","startYear":2016,"startMonth":5,"endYear":2020,"endMonth":7,"statusDescription":"Completed","principalInvestigators":[{"contactId":507410,"canUserEdit":false,"firstName":"Jeremy","lastName":"Senne","fullName":"Jeremy A Senne","fullNameInverted":"Senne, Jeremy A","middleInitial":"A","primaryEmail":"jsenne@appliedcomposites.com","publicEmail":true,"nacontact":false}],"programDirectors":[{"contactId":206378,"canUserEdit":false,"firstName":"Jason","lastName":"Kessler","fullName":"Jason L Kessler","fullNameInverted":"Kessler, Jason L","middleInitial":"L","primaryEmail":"jason.l.kessler@nasa.gov","publicEmail":true,"nacontact":false}],"programExecutives":[{"contactId":215154,"canUserEdit":false,"firstName":"Jennifer","lastName":"Gustetic","fullName":"Jennifer L Gustetic","fullNameInverted":"Gustetic, Jennifer L","middleInitial":"L","primaryEmail":"jennifer.l.gustetic@nasa.gov","publicEmail":true,"nacontact":false}],"programManagers":[{"contactId":62051,"canUserEdit":false,"firstName":"Carlos","lastName":"Torrez","fullName":"Carlos Torrez","fullNameInverted":"Torrez, Carlos","primaryEmail":"carlos.torrez@nasa.gov","publicEmail":true,"nacontact":false}],"projectManagers":[{"contactId":1781095,"canUserEdit":false,"firstName":"Matthew","lastName":"Chamberlain","fullName":"Matthew K Chamberlain","fullNameInverted":"Chamberlain, Matthew K","middleInitial":"K","primaryEmail":"matthew.k.chamberlain@nasa.gov","publicEmail":true,"nacontact":false},{"contactId":461333,"canUserEdit":false,"firstName":"Theresa","lastName":"Stanley","fullName":"Theresa M Stanley","fullNameInverted":"Stanley, Theresa M","middleInitial":"M","primaryEmail":"theresa.m.stanley@nasa.gov","publicEmail":true,"nacontact":false},{"contactId":368183,"canUserEdit":false,"firstName":"Paul","lastName":"Danehy","fullName":"Paul M Danehy","fullNameInverted":"Danehy, Paul M","middleInitial":"M","primaryEmail":"paul.m.danehy@nasa.gov","publicEmail":true,"nacontact":false},{"contactId":266221,"canUserEdit":false,"firstName":"Keith","lastName":"Woodman","fullName":"Keith L Woodman","fullNameInverted":"Woodman, Keith L","middleInitial":"L","primaryEmail":"keith.l.woodman@nasa.gov","publicEmail":true,"nacontact":false},{"contactId":3164655,"canUserEdit":false,"firstName":"Matt","lastName":"Chamberlain","fullName":"Matt Chamberlain","fullNameInverted":"Chamberlain, Matt","primaryEmail":"matthew.k.chamberlain@nasa.gov","publicEmail":true,"nacontact":false}],"coInvestigators":[{"contactId":379432,"canUserEdit":false,"firstName":"Quinn","lastName":"Mcallister","fullName":"Quinn Mcallister","fullNameInverted":"Mcallister, Quinn","primaryEmail":"Qmcallister@Sdcomposites.Com","publicEmail":true,"nacontact":false}],"website":"","libraryItems":[{"file":{"fileExtension":"pdf","fileId":292865,"fileName":"briefchart","fileSize":9287436,"objectId":289382,"objectType":{"lkuCodeId":889,"code":"LIBRARY_ITEMS","description":"Library Items","lkuCodeTypeId":182,"lkuCodeType":{"codeType":"OBJECT_TYPE","description":"Object Type"}},"objectTypeId":889,"fileSizeString":"8.9 MB"},"files":[{"fileExtension":"pdf","fileId":292865,"fileName":"briefchart","fileSize":9287436,"objectId":289382,"objectType":{"lkuCodeId":889,"code":"LIBRARY_ITEMS","description":"Library Items","lkuCodeTypeId":182,"lkuCodeType":{"codeType":"OBJECT_TYPE","description":"Object Type"}},"objectTypeId":889,"fileSizeString":"8.9 MB"}],"id":289382,"title":"Briefing Chart","description":"Advanced Composite Truss (ACT) Printing for Large Solar Array Structures, Phase II Briefing 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Structures","startTrl":2,"currentTrl":4,"endTrl":4,"benefits":"The SBIR Phase I project focus is on the near-term Asteroid Redirect Mission which requires deployable structure capabilities. SDC will demonstrate feasibility of continuous ACT structure printing for use with deployable structures based on the ARM system design and mission objectives. The ultimate intent of the Phase I project is to develop and evaluate a new, novel deployable structure mechanism with mission and structure tailorability. SDC has aligned the schedule and scope of the SBIR project with NASA's proposed ARM development roadmap. A Phase II SBIR will develop the continuous ACT printing process by developing a prototype machine to perform the manufacturing. The Phase II will also see improved analysis and design techniques with the manufacturability, strength-to-weight ratio, and structural capabilities of the structures at the heart of the development effort. According to NASAs current plans for ARM, the mission will be developed in the early 2020 decade, for which SDC is confident that working continuous ACT printing machine will be available for deployable structures. Further development plans for continuous ACT printed structures include all space missions that require deployable structures for SEP, as well as in-situ structural repairs for any and all spacecraft such as the ISS.
The need for a low-cost, light-weight, space deployable structure is far broader than the proposed scope of this Phase I project. SDC recognizes the high potential for continuous ACT structures to be an enabling technology for future satellite and ISS or other future space station structures. Long-term low-earth orbit satellites could utilize these structures minimize launch volume/weight. This type of deployable structure could be applied and tailored to each mission's specific structural needs, with the process being easily scalable and reprogrammable. Continuous ACT printed structures could be used as in-situ structural repairs for the ISS, additional deployable structure for solar arrays for all types of space crafts, as well as numerous other structural applications.","description":"San Diego Composites has developed a game-changing concept for the in-situ manufacture of advanced composite structures from aboard a spacecraft. This concept uses a combination of proven composite manufacturing processes, such as filament winding, pultrusion, and UV curing resins systems. The system has the capability to \"print\" advanced composite truss (ACT) structures from raw materials carried up during launch. This concept minimizes launch volume allowing for space for other mission-critical equipment, and allows for the deployment of much larger structures than the current state-of-the art. Deployed structures using SDC's continuous Advanced Composite Truss (ACT) printing system would be limited in length only by the ultimate structural capabilities of the material and truss structure. While the application addressed for this particular proposal deals with structures in the hundreds of feet, this concept could be extended to create structures in excess of 1000s of feet if tailored for a different given integration platforms. There are many advantages to this methodology. First of all, the entire produced structure is load carrying without fasteners, joints, or secondary materials. Secondly, high modulus fibers can be used as the primary load carrying material creating the efficient structure from a stiffness/weight perspective. Another advantage of the process is that it can be programmable for \"printing\" the optimized structures. Also, the structures are manufactured and cured in space after all of the high vibration loading associated with launch are over. SDC's continuous ACT printing method can also be integrated with the deployment strategy for a solar sail or array. This would maximize the use of the hardware and help to justify the light-weight machine.","startYear":2015,"startMonth":6,"endYear":2015,"endMonth":12,"statusDescription":"Completed","website":"","program":{"acronym":"SBIR/STTR","active":true,"description":"
The NASA SBIR and STTR programs fund the research, development, and demonstration of innovative technologies that fulfill NASA needs as described in the annual Solicitations and have significant potential for successful commercialization. If you are a small business concern (SBC) with 500 or fewer employees or a non-profit RI such as a university or a research laboratory with ties to an SBC, then NASA encourages you to learn more about the SBIR and STTR programs as a potential source of seed funding for the development of your innovations.
The SBIR and STTR programs have 3 phases:
The SBIR and STTR Phase I contracts last for 6 months with a maximum funding of $125,000, and Phase II contracts last for 24 months with a maximum funding of $750,000 - $1.5 million.
Opportunity for Continued Technology Development Post-Phase II:
The NASA SBIR/STTR Program currently has in place two initiatives for supporting its small business partners past the basic Phase I and Phase II elements of the program that emphasize opportunities for commercialization. Specifically, the NASA SBIR/STTR Program has the Phase II Enhancement (Phase II-E) and Phase II eXpanded (Phase II-X) contract options.
Please review the links below to obtain more information on the SBIR/STTR programs.
Provides an overview of the SBIR and STTR programs as implemented by NASA
Provides access to the annual SBIR/STTR Solicitations containing detailed information on the program eligibility requirements, proposal instructions and research topics and subtopics
Schedule and links for the SBIR/STTR solicitations and selection announcements
Federal and non-Federal sources of assistance for small business
Search our complete archive of awarded project abstracts to learn about what NASA has funded
Still have questions? Visit the program FAQs
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The SBIR and STTR programs have 3 phases:
The SBIR and STTR Phase I contracts last for 6 months with a maximum funding of $125,000, and Phase II contracts last for 24 months with a maximum funding of $750,000 - $1.5 million.
Opportunity for Continued Technology Development Post-Phase II:
The NASA SBIR/STTR Program currently has in place two initiatives for supporting its small business partners past the basic Phase I and Phase II elements of the program that emphasize opportunities for commercialization. Specifically, the NASA SBIR/STTR Program has the Phase II Enhancement (Phase II-E) and Phase II eXpanded (Phase II-X) contract options.
Please review the links below to obtain more information on the SBIR/STTR programs.
Provides an overview of the SBIR and STTR programs as implemented by NASA
Provides access to the annual SBIR/STTR Solicitations containing detailed information on the program eligibility requirements, proposal instructions and research topics and subtopics
Schedule and links for the SBIR/STTR solicitations and selection announcements
Federal and non-Federal sources of assistance for small business
Search our complete archive of awarded project abstracts to learn about what NASA has funded
Still have questions? Visit the program FAQs
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