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Because OFDR-based fiber interrogation systems rely upon interferometry between sensors with respect to a unique reference length, the excitation source (laser) must lase at a single longitudinal mode (SLM). If the excitation source contains multiple modes, the resulting beat frequency becomes a super-position of the multiple frequencies caused by the modes; as a result, the sensor cannot be accurately defined in the Fourier domain. For OFDR systems with high sensing ranges, a continuous wavelength tunable laser must be used to accommodate the resonant wavelength shift of the fiber sensors due to environmental changes. External cavity lasers (ECLs) have been used due to their narrow linewidth and ability to lase at a SLM with no mode-hopping between steps. However, the mechanical complexity associated with tuning, susceptibility to vibration and shock, and high price point leave much to be desired. To overcome the limitations of OFDR-based FOSS systems resulting from non-ideal excitation sources, NASA has developed a narrow linewidth solid-state laser based on the Distributed Feedback (DFB) laser. NASAs laser is continuously tuned by manipulating the laser cavitys temperature via a thermal-electric cooler feedback system. This continuous wavelength tuning generates a clean clock signal within an auxiliary interferometer, while the laser simultaneously interrogates multiple FBGs to produce a clean sensing interferometer. A Fourier domain spectrograph is used to show the unique frequency (i.e., location) of each FBG. While NASAs excitation source provides several performance advantages over conventional lasers used in OFDR, it is also highly compact and one eighth the cost of the ECLs traditionally used as excitation sources in OFDR-based systems. The laser has no moving parts, which also substantially improves system reliability. Originally developed to demonstrate a low-cost interrogator for liquid level sensing in oil tanks, NASAs compact, temperature-tuned OFDR laser can be applied wherever OFDR-based fiber optic sensing is desirable. Additional applications may include temperature distribution sensing, strain sensing, pressure sensing, and more. NASA AFRC has strong subject matter expertise in fiber optic sensing systems, and has developed several patented technologies that are available for commercial licensing. For more information about the full portfolio of FOSS technologies, visit: https://technology-afrc.ndc.nasa.gov/featurestory/fiber-optic-sensing

The QCL source addresses the challenges of inefficiency, high power consumption, and bulky designs typically associated with existing solutions. It is fabricated with 80 to 100 alternating layers of semiconductor materials, each layer only a few microns thick. These layers create a cascade effect that amplifies terahertz-energy photon generation while consuming significantly less voltage. To mitigate the natural beam dissipation of QCLs, the source is integrated with a waveguide and thin optical antenna, reducing signal loss by 50%. Additionally, the waveguide employs a flared design with a diagonal feed horn, achieving high modal confinement and increasing beam coupling efficiency to 82%, compared to 37% in conventional setups. This compact design, smaller than a U.S. quarter, fits within payload constraints and enables high-powered terahertz beams for precise spectroscopic measurements. The terahertz transceiver enhances measurement precision by integrating two back-to-back hybrid couplers and Schottky diodes as detectors, providing a 35 dB dynamic range. Operating in the 2.0–3.2 THz frequency range, the transceiver is optimized for versatility across astrophysics, heliophysics, and planetary science applications. It seamlessly couples the QCL-generated signal onto the waveguide, ensuring stable and accurate spectroscopic data collection. This compact and energy-efficient transceiver delivers exceptional sensitivity, enabling it to analyze planetary materials, atmospheric components, and interstellar phenomena with unmatched resolution. With its compact, tunable design and high spectral resolution, the QCL source and transceiver represents a significant advancement for remote sensing and planetary surface characterization, offering a versatile solution for both NASA and commercial applications. The QCL system is at technology readiness level (TRL) 4 (component and/or breadboard validation in lab) and is available for patent licensing.

The new fabrication method is an electron lithography scheme enabling monolithic integration of multiple photonic devices on a single PIC. The technology was demonstrated by integrating both a widely-tunable distributed Bragg reflector (DBR) and distributed feedback (DFB) lasers on the same substrate. By controlling the central gap width and etch depth along the laser mirror length (shown in the figure below) the reflectivities can be tuned and the desired laser characteristics can be achieved without additional lithography cycles. Initially demonstrated on an indium phosphide substrate with DBR and DFB elements, the platform technology shows promise for various other materials and devices like III-V and II-VI semiconductors, silicon-on-insulator (SOI), and planar lightwave circuits (PLCs). With this versatility, the invention described here can streamline PIC production across diverse applications. Proof-of-concept results showcase the lithographic technique’s ability to produce high-performance photonic devices with side-mode suppression ratios over 50 dB (figure on the right) and output powers exceeding 5 mW. These metrics, combined with the lithographic simplicity, highlight the technology’s potential to reduce costs and accelerate PIC manufacturing. Please note that NASA does not manufacture products itself for commercial scale.

This invention provides a new method for optical data transmissions from satellites using laser arrays for laser beam pointing. The system is simple, static, compact, and provides accurate pointing, acquisition, and tracking (PAT). It combines a lens system and a vertical-cavity surface-emitting laser VCSEL)/Photodetector Array, both mature technologies, in a novel way for PAT. It can improve the PAT system's size, weight, and power (SWaP) in comparison to current systems. Preliminary analysis indicates that this system is applicable to transmissions between satellites in low-Earth orbit (LEO) and ground terminals. Computer simulations using this design have been made for the application of this innovation to a CubeSat in LEO. The computer simulations included modeling the laser source and diffraction effects due to wave optics. The pointing used a diffraction limited lens system and a VCSEL array. These capabilities make it possible to model laser beam propagation over long space communication distances. Laser beam pointing is very challenging for LEO, including science missions. Current architectures use dynamical systems, (i.e., moving parts, e.g., fast-steering mirrors (FSM), and/or gimbals) to turn the laser to point to the ground terminal, and some use vibration isolation platforms as well. This static system has the potential to replace the current dynamic systems and vibration isolation platforms, dependent on studies for the particular application. For these electro-optical systems, reaction times to pointing changes and vibrations are on the nanosecond time scale, much faster than those for mechanical systems. For LEO terminals, slew rates are not a concern with this new system.

The conventional approaches for measuring focused laser differential interferometry either use a single-point mechanism that cannot calculate velocity or a system that creates non-parallel beams in the testing zone, causing differences in time to travel between beams throughout the testing zone, adding a level of uncertainty to velocity measurements. For this technology, the inventors determined that the best approach is to use a method that ensures all laser beams propagating between the transmitter and receiver sides of the instrument are parallel to one another. This is done by crossing two orthogonally polarized beams at a Wollaston prism located just ahead of the field lens on the transmitter side of the FLDI. The polarization orientation of the two crossing beams must be at ±45 degrees to one another so that the Wollaston prism can further split the beams by a small angle (this gives the instrument its sensitivity to density fluctuations at each measurement point). The use of wedge prisms (that comprise the beam crossing system) to redirect the split beams such that they cross the optical axis minimizes any distortion imparted to the beams. This is in contrast to the use of a spherical focusing lens to redirect the split beams, which can impart undesirable distortions to the beams and affect the focusing properties of the FLDI instrument between its transmitter and receiver sides.

NASA’s laser mount technology introduces a unique flexible crystal mount to accommodate the dynamics of thermal expansion to eliminate unsymmetrical thermally induced mechanical stresses on the crystal. In addition, while the mount accommodates thermal expansion, it also offers fixed placement of the crystal to maintain alignment and provides continuous and uniform surface contact between the mount and crystal for rapid dissipation of heat. The mount is compatible with any heat sink reservoir. The mount design allows unrestrained thermal expansion of the crystal in two dimensions (i.e. a- and c- axes) because of the design shown in the figure below. The L-shape blocks also deliver cooling to the crystal by providing a path to the heat sink reservoir. The L-shape blocks are manufactured with a high thermal conductivity material such as copper. A softer material with high thermal conductivity such as indium is used to buffer the interface between the crystal and the L-shape blocks surfaces. A coolant medium acts to transfer the heat from the crystal to the cooled mount. Cooling can be provided in different ways – for example by water or by heat pipes with radiator (for use in space). The springs used to hold the laser crystal also provide the adjustment method to align the beam, and once aligned, the crystal mount is very stable. The related patent is now available to license. Please note that NASA does not manufacture products itself for commercial sale.

LWDC technology enables an improved channel wall nozzle with an outer liner that is fused to the inner liner to contain the coolant. It is an additive manufacturing technology that builds upon large-scale cladding techniques that have been used for many years in the oil and gas industry and in the repair industry for aerospace components. LWDC leverages wire freeform laser deposition to create features in place and to seal the coolant channels. It enables bimetallic components such as an internal copper liner with a superalloy jacket. LWDC begins when a fabricated liner made from one material, Material #1, is cladded with an interim Material #2 that sets up the base structure for channel slotting. A robotic and wire-based fused additive welding system creates a freeform shell on the outside of the liner. Building up from the base, the rotating weld head spools a bead of wire, closing out the coolant channels as the laser traverses circumferentially around the slotted liner. This creates a joint at the interface of the two materials that is reliable and repeatable. The LWDC wire and laser process is continued for each layer until the slotted liner is fully closed out without the need for any filler internal to the coolant channels. The micrograph on the left shows the quality of the bond at the interface of the channel edge and the closeout layer; on the right is a copper channel closed out with stainless.

A new method is described for optical data transmissions from satellites using laser arrays for fine pointing of laser beams that use body pointing. It combines a small lens system and a VCSEL/Photodetector Array in a novel way to provide a fine pointing capability for laser beams that are pointed by body pointing of a CubeSat. As Fig. 1 shows, an incoming laser beam (green or blue, with rightward arrows), transmitted from a ground terminal, enters the lens system, which directs it to an element of the pixel array (gray rectangle). Each element, or pixel, consists of a VCSEL component/photodetector pair. The photodetector detects the incoming beam, and the VCSEL component returns a modulated beam to the lens system (green or blue, with leftward arrows), which sends it to the ground terminal. As the incoming beam changes direction, e.g., from the blue to the green incoming direction, this change is detected by the adjacent photodetector, and the laser paired with that photodetector is turned on to keep the outgoing laser beam on target. The laser beams overlap so that the returning beam continues to point at the ground terminal. The VCSEL component may consist of a single VCSEL or a cluster of VCSELs. Figure 2 shows the propagation of two overlapping laser beams. The system can very accurately point finely focused diffraction-limited laser beams. Also, simultaneous optical multiple access (OMA) is possible from different transceivers within the area covered by the laser array. For this electro-optical system, reaction times to pointing changes and vibrations are on the nanosecond time scale, much faster than mechanical fine pointing systems.

The LiDAR with Reduced-Length Linear Detector Array improves upon a prior fast-wavelength-steering, time-division-multiplexing 3D imaging system with two key advancements: laser linewidth broadening to reduce speckle noise and improve the signal-to-noise ratio, and the integration of a slow-scanning mirror with wavelength-steering technology to enable 2D swath mapping capabilities. Range and velocity are measured using the time-of-flight of short laser pulses. This highly efficient LiDAR incorporates emerging technologies, including a photonic integrated circuit seed laser, a high peak-power fiber amplifier, and a linear-mode photon-sensitive detector array. With no moving parts, the transmitter rapidly steers a single high-power laser beam across up to 2,000 resolvable footprints. Fast beam steering is achieved through an innovative high-speed wavelength-tuning technology and a single grating design that enables wavelength-to-angle dispersion while rejecting solar background for all transmitted wavelengths. To optimize receiver power and reduce data volume, sequential returns from up to 10 different tracks are time-division-multiplexed and digitized by a high-speed digitizer for surface ranging. Each track’s atmospheric return can be digitized in parallel at a lower resolution using an ultra-low-power digitizer. Originally developed by NASA for SmallSat missions, this system’s precise and accurate observation capabilities—combined with reduced costs, size, weight, and power constraints—make it applicable to a wide range of LiDAR applications. The LiDAR with Reduced-Length Linear Detector Array is currently at Technology Readiness Level (TRL) 4 (validated in a laboratory environment) and is available for patent licensing.

This method leverages advanced computational modeling to evaluate localized heating conditions and fusion metrics and quantify defect risks dynamically, allowing for optimized build files and process adjustments that drastically improve the final component. The model can be trained using PPF and print samples from an AM machine's prior builds to learn correlations between the machine's instructions, behavior during build, and final product quality. By integrating machine feedback metrics, model-based thermal and fusion metrics, and in-situ sensor metrics, the model learns predictive signatures that allow it to quantify localized defect probability in PBF laser beam metals. Manufacturers can employ this method to understand the reproducibility of their prints and perform defect compensation before parts are fully deployed, improving quality, reliability, and success. Particularly useful to industries that require stringent certification of safety-critical components, such as the aerospace, space, medical, and automotive sectors, this method can be flexibly deployed globally or adapted to specific AM machines. By predicting the probability of defects before and during production, 3D printing service providers and AM equipment manufacturers can save significant amounts of time and money while drastically reducing part variability. This predictive capability also allows organizations to certify parts faster and ensure consistent material properties, which is essential for meeting rigorous performance and safety standards. This is method is currently available for patent licensing (no software included).