Inflatable space structures

Abstract: Inflatable structures offer the potential of compactly stowing lightweight structures, which assume a fully deployed state in space. An important category of space inflatables are cylindrical booms, which may form the structural members of trusses or the support structure for solar sails. Two critical and interdependent aspects of designing inflatable cylindrical booms for space applications are i) packaging methods that enable compact stowage and ensure reliable deployment, and ii) rigidization techniques that provide long-term structural ridigity after deployment. The vast literature in these two fields is summarized to establish the state of the art.

Abstract: Photogrammetry--the science of calculating 3D object coordinates from images--is a flexible and robust approach for measuring the static and dynamic characteristics of future ultra-lightweight and inflatable space structures (a.k.a., Gossamer structures), such as large membrane reflectors, solar sails, and thin-film solar arrays. Shape and dynamic measurements are required to validate new structural modeling techniques and corresponding analytical models for these unconventional systems. This paper summarizes experiences at NASA Langley Research Center over the past three years to develop or adapt photogrammetry methods for the specific problem of measuring Gossamer space structures. Turnkey industrial photogrammetry systems were not considered a cost-effective choice for this basic research effort because of their high purchase and maintenance costs. Instead, this research uses mainly off-the-shelf digital-camera and software technologies that are affordable to most organizations and provide acceptable accuracy.

Abstract: The emerging class of direct manufacturing processes known as Solid Freeform Fabrication (SFF) employs a focused energy beam and metal feedstock to build structural parts directly from computer aided design (CAD) data. Some variations on existing SFF techniques have potential for application in space for a variety of different missions. This paper will focus on three different applications ranging from near to far term to demonstrate the widespread potential of this technology for space-based applications. One application is the on-orbit construction of large space structures, on the order of tens of meters to a kilometer in size. Such structures are too large to launch intact even in a deployable design; their extreme size necessitates assembly or erection of such structures in space. A low-earth orbiting satellite with a SFF system employing a high-energy beam for high deposition rates could be employed to construct large space structures using feedstock launched from Earth. A second potential application is a small, multifunctional system that could be used by astronauts on long-duration human exploration missions to manufacture spare parts. Supportability of human exploration missions is essential, and a SFF system would provide flexibility in the ability to repair or fabricate any part that may be damaged or broken during the mission. The system envisioned would also have machining and welding capabilities to increase its utility on a mission where mass and volume are extremely limited. A third example of an SFF application in space is a miniaturized automated system for structural health monitoring and repair. If damage is detected using a low power beam scan, the beam power can be increased to perform repairs within the spacecraft or satellite structure without the requirement of human interaction or commands. Due to low gravity environment for all of these applications, wire feedstock is preferred to powder from a containment, handling, and safety standpoint. The energy beams may be either electron beam or laser, and the developments required for either energy source to achieve success in these applications will be discussed.