Novel Overhang Support Designs for Powder-Based Electron Beam Additive Manufacturing (EBAM)

The NASA innovation is based on a tessellation algorithm to break up a curved surface into identically sized equilateral surface polygons. Tessellation is a term used in mathematics that describes the process of deconstructing a surface into non-overlapping shapes with no gaps. Using this NASA innovation enables a curved-surface truss structure to be designed and built using all identical module and strut components. A key feature of this innovation is the use of a “multi-nut” connector, which enables curved surface truss structures to be assembled from identical truss modules. Uniform truss modules with customizable multi-nut connectors can be used to construct a curved-surface structure. The algorithm is a design approach for any size or surface shape. The NASA innovation represents a major breakthrough due to: • Versatility to a variety of planar and curved structure shapes (cylinder, sphere, etc.) • Ability to change the shape simply by updating the “multi-nut” connectors • Commonality of truss modules and components • Ease of assembly • Efficiency of construction and weight • Robotic assembly and servicing. In addition to a range of space related applications – mirrors, antennas, habitats, storage containers, etc. – the innovation is also directly applicable to general terrestrial assembly of systems with curvature, including for example sports stadiums, airports, aquariums, convention centers, or bridges.

The instrument uses two synchronized fixtures that rotate in equal and opposite directions, imparting fully reversible bending so the same surface experiences alternating tension and compression, mitigating buckling and alignment sensitivities common in uniaxial fatigue setups. A single motor, reduction gearbox, and shaft translate drive motion into counter rotation at both ends, while round tip, width spanning clamps distribute pressure to minimize corner stress concentrations and protect delicate specimens. Users can select pure bending or four point bending modes and adjust rotation amplitude and torque through an integrated controller, delivering repeatable cyclic loading in a compact, standalone system. Distinctive advantages include reliable testing of asymmetric geometries (laps, fillets), thin sheets, additively manufactured parts, and brittle ceramics without large dual actuator frames. This can consolidate multiple flexure methods into one benchtop mechanism. Its modular layout and adjustable fixtures integrate smoothly with common lab workflows and OEM platforms, helping teams accelerate evaluations without major reconfiguration of existing equipment. Potential commercial markets include instrument OEMs and suppliers of materials testing systems and accessories serving aerospace, automotive, academic, and contract laboratories. This technology is assessed at a TRL 6 and is ready for patent licensing.

This technology (AERoBOND) enables the assembly of large-scale, complex composite structures while maintaining predictable mechanical and material properties. It does so by using a novel barrier-ply technology consisting of an epoxy resin/prepreg material with optimal efficiency, reliability, and performance. The barrier-ply materials prevent excessive mixing between conventional composite precursors and stoichiometrically-offset epoxy precursors during the cure process by forming a gel early in the cure cycle before extensive mixing can occur. The barrier ply is placed between the conventional laminate preform and the stoichiometrically-offset ply or plies placed on the preform surface, thus preventing excessive mass transfer between the three layers during the cure process. In practice, the barrier ply could be combined with the offset ply to be applied as a single, multifunctional surfacing layer enabling unitized assembly of large and complex structures. The AERoBOND method is up to 40% faster than state-of-the-art composite manufacturing methods, allows for large-scale processing of complex structures, eliminates the potential for weak bond failure modes, and produces composites with comparable mechanical properties as compared with those prepared by co-cure.

Dispersion Enhanced Aluminum Alloys improve the additive manufacturing performance of high-strength aluminum alloys by modifying the alloy powder with uniformly dispersed nano-sized ceramic particles. Building on the dispersion and acoustic mixing methods developed during the creation of NASA Glenn's GRX-810 technology, researchers use an acoustic field to attach nanoscale alumina dispersoids to the surface of each aluminum alloy powder particle. During mixing, acoustic energy creates rapid micro-vibrations that cause the alumina particles to collide with the metal powder, embed against its surface, and distribute into a uniform shell that surrounds each particle. This produces a composite powder in which every aluminum particle carries its own evenly spaced ceramic nucleation sites. When the composite powder is delivered into an additive manufacturing process such as laser powder bed fusion or directed energy deposition, the aluminum alloy melts while the alumina dispersoids remain solid due to their significantly higher melting temperature. As the molten pool flows and mixes, the dispersoids remain suspended throughout the liquid region. During solidification, these solid particles interrupt grain growth and serve as nucleation points that promote the formation of fine equiaxed grains. This refined microstructure distributes thermal stresses more uniformly and disrupts the crack initiation mechanisms that typically occur in high-strength alloys like AA 2050. By stabilizing the alloy during solidification, the technology enables these advanced materials to be printed with greater reliability, improved geometric control, and more consistent mechanical behavior across the final product. The enhanced alloy technology is available for patent licensing.

The Multi-Link Spherical Joint developed at NASA Johnson Space Center provides a substantial improvement over typical joints in which only two linearly actuated links move independently from one another. It was determined that the rotation point of a trussed link needed to be collocated at a shared point in space for maximum articulation. If not allowed separate rotation, the line of action through a universal joint and hinge acts effectively as another linkage. This leads to a much more complex and uncontrollable structure, especially when considering multiple dimensions. Comprising the Multi-Link Spherical Joint, a spherical shell encases the cupped ends of each six possible attachments and allows each of those attachments to be independently controlled and rotated without inhibiting the motion of the others. To do this, each link is precisely limited to 15 degrees of rotation off the link centerline, thus allowing a total of 30 degrees of rotation for each link. The shell-and-cup structure can handle the loads of linear actuators that may be used to control and vary the geometry of a truss system utilizing the new joint technology. The calculated operating load that the truss system must handle can be used to scale the size of the joint, further allowing customization of any potential truss system. Additionally, the incorporated linear actuators can be controlled and powered by wiring routed through the joint without putting undo stress on the wires during operation. Accordingly, this innovative joint technology enables more efficient deployment and precise operation of articulating structures. The Multi-Link Spherical Joint is at technology readiness level (TRL) 4 (component and/or breadboard validation in laboratory environment) and is available for patent licensing. Please note that NASA does not manufacture products itself for commercial sale.