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Formation of the inventive polymer composite matrix begins by growing carbon nanotubes directly on a veil substrate. The carbon nanotubes are grown from both sides of a non woven carbon fiber mat. The carbon nanotubes can be single or multi walled and can be grown to predetermined lengths. The veiled substrate is positioned between carbon fiber/ polymer prepreg layers such that the carbon nanotubes protrude into the reinforcement layers. The polymer composite matrix formed following curing of the resin exhibits improved interlaminar strength, fracture toughness and impact resistance. Because of the thinness of the veil layer, electricity can pass from conductive carbon nanotubes on one side of the veil to conductive carbon nanotubes on the other side of the veil. Electricity can also pass between two veils intercalated into the same reinforcement layer when the length of the nanotubes is sufficiently long enough to provide overlap within the reinforcement layers.

To overcome the challenges of conventional molding, researchers at NASA Glenn have developed a rapid prototyping approach for three-dimensional printing of polymer aerogels using deposition into a viscous, sacrificial support medium. The sacrificial support stabilizes the aerogel deposition, allowing precise layer-by-layer construction of self-supporting aerogel networks that would otherwise be unprintable in air. Following printing and gelation of the polymer network, the printed structure is gently removed from the sacrificial medium, yielding a freestanding aerogel precursor with high shape fidelity. This method decouples printability from intrinsic material viscosity and enables rapid iteration of aerogel geometries, offering a scalable pathway for additive manufacturing of ultra-lightweight, architected polymer aerogels with tailored geometries, while retaining microstructural, mechanical, and thermal properties. The method involves: 1. Forming a solution comprised of a polymer precursor, cross-linker, solvent, and catalyst to create a dilute polymer solution. 2. 3D printing the polymer precursor directly into the sacrificial support medium. 3. Following printing and network formation, the structure is removed from the sacrificial medium through a low-stress extraction process, yielding a freestanding polymer aerogel precursor that retains the as-printed geometry with high fidelity. The sacrificial medium functions as a temporary, conformal support matrix that stabilizes each deposited droplet or filament in situ, enabling freeform construction of aerogel. This strategy enables the fabrication of highly porous, interconnected networks with controlled feature resolution across multiple length scales, while maintaining the intrinsic low density and high surface area required for aerogel performance.

NASA’s HYDRA system enables a new approach in routing the RFID signal, greatly increasing extensibility and the number of antennas that can be served by a single reader. However, increasing the number of antennas in any environment is often undesirable unless the antenna size is inconspicuous. Basing this RFID dual mode antenna on a quarter-wavelength structure allows it to be smaller than an antenna designed for half-wavelength structure, reducing overall mass. NASA’s RFID dual mode antenna is enabled by utilizing two different types of resonance modes – a “slot” mode and a microstrip “patch” mode. An innovative feed architecture allows for coupling from the RFID reader into both modes, with the impedance of each mode approximately equal at respective resonant frequencies. The antenna is designed such that each mode resonates at a different portion of the operating bandwidth, and further with each mode radiating an orthogonal polarization to the other. Frequency-hopping RFID protocols, used in conjunction with this antenna, result in the polarization diversity required for readers to reliably communicate with arbitrarily oriented RFID tags. Numerous commercial applications exist for this RFID dual mode antenna. Examples may include usage in a multiple antenna architecture that is connected to a single reader in an open-air region, in a small, enclosed region such as a cabinet drawer, or through a combination of open and closed regions. This RFID dual mode antenna has a technology readiness level (TRL) 7 (system prototype demonstrated in an operational environment) and is now available for patent licensing. Please note that NASA does not manufacture products itself for commercial sale.