Blow Dryers And Metal Shears: Hacks Of Early Falcon 9 Flights

June 13, 2020 by 10 Comments

Orbiting over our heads right now are two human beings who flew to the International Space Station in a SpaceX Crew Dragon vehicle on top of a Falcon 9. The majority of coverage focused on the years since human spaceflight last launched from Florida, but [Eric Berger] at Ars Technica reminds us it also makes for a grand ten-year celebration of the SpaceX workhorse rocket by sharing some stories from its early days.

Falcon 9 is a huge presence in the global space launch industry today, but ten years ago the future of a young aerospace company was far from certain. The recent uneventful launch is the result of many lessons learned in those ad-hoc days. Some early Falcon 9 flights were successful because the team decided some very unconventional hacks were worth the risk that paid off. A bit of water intrusion? Dry it out with a blow dryer and seal it back up. Small tear in a rocket nozzle? Send in someone to trim a few inches with shears (while the rocket was standing vertical on the launchpad).

Industry veterans appalled at “a cowboy attitude” pounced on every SpaceX failure with “I told you so.” But the disregard for convention is intentional, documented in many places like this old Wired piece from 2012. Existing enshrined aerospace conventions meant the “how” was preserved but the “why” was reduced to “we’ve always done it this way” rarely re-evaluated in light of advancements. Plus the risk-averse industry preferred staying with flight-proven designs, setting up a Catch-22 blocking innovation. SpaceX decided to go a different way, rapidly evolving the Falcon 9 and launching at a high cadence. Learning from all the failures along the way gave them their own set of “why” to back up their “how” growing far beyond blow dryers and metal shears. We’re happy to see the fail-learn-improve cycle at the heart of so many hacker projects have proven effective to send two astronauts to the space station and likely beyond.

[Photo: SpaceX Crew Demo-2 on the launch pad]

3D Printing Nuclear Reactors For Fun And Profit

June 8, 2020 by 18 Comments

Over the past decades, additive manufacturing (AM, also known as 3D printing) has become increasingly common in manufacturing processes. While immensely helpful in the prototyping of new products by allowing for rapid turn-around times between design and testing, these days additive manufacturing is used more and more often in the production of everything from small production runs of custom enclosures to hard to machine components for rocket engines.

The obvious advantage of additive manufacturing is that they use generic equipment and common materials as input, without requiring expensive molds as in the case of injection molding, or extensive, wasteful machining of raw materials on a lathe, mill, and similar equipment. All of the manufacturing gets reduced to a 3D model as input, one or more input materials, and the actual device that converts the 3D model into a physical component with very limited waste.

In the nuclear power industry, these benefits haven’t gone unnoticed, which has led to 3D printed parts being developed for everything from keeping existing plants running to streamlining spent fuel reprocessing and even the printing of entire nuclear reactors.

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NASA’s Long-Delayed Return To Human Spaceflight

June 1, 2020 by 55 Comments

With the launch of the SpaceX Demo-2 mission, the United States has achieved something it hasn’t done in nearly a decade: put a human into low Earth orbit with a domestic booster and vehicle. It was a lapse in capability that stretched on far longer than anyone inside or outside of NASA could have imagined. Through a series of delays and program cancellations, the same agency that put boot prints on the Moon and built the iconic Space Shuttle had been forced to rely on Russia to carry its astronauts into space since 2011.

NASA would still be waiting to launch its own astronauts had they relied on America’s traditional aerospace giants to get the job done. The inaugural flight of the Boeing CST-100 “Starliner” to the International Space Station in December was an embarrassing failure that came perilously close to losing the unmanned capsule. A later investigation found that sloppy software development and inconsistent testing had caused at least two major failures during the mission, which ultimately had to be cut short as the vehicle couldn’t even reach the altitude of the ISS, to say nothing of making a docking attempt. NASA and Boeing have since agreed to attempt another test of the CST-100 sometime before the end of the year, though a delay into 2021 seems almost inevitable due to the global pandemic.

But America’s slow return to human spaceflight can’t be blamed on the CST-100, or even Boeing, for that matter. Since the retirement of the Space Shuttle, NASA has been hindered by politics and indecisiveness. With a constantly evolving mandate from the White House, the agency’s human spaceflight program has struggled to make significant progress towards any one goal.

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Searching For Alien Life With The Sun As Gravitational Telescope

April 21, 2020 by 19 Comments

Astronomy is undoubtedly one of the most exciting subjects in physics. Especially the search for exoplanets has been a thriving field in the last decades. While the first exoplanet was only discovered in 1992, there are now 4,144 confirmed exoplanets (as of 2nd April 2020). Naturally, we Sci-Fi lovers are most interested in the 55 potentially habitable exoplanets. Unfortunately, taking an image of an Earth 2.0 with enough detail to identify potential features of life is impossible with conventional telescopes.

The solar gravitational lens mission, which has recently been selected for phase III funding by the NASA Innovative Advanced Concepts (NIAC) program, is aiming to change that by taking advantage of the Sun’s gravitational lensing effect. Continue reading “Searching For Alien Life With The Sun As Gravitational Telescope” →

Getting To Space Is Even Harder During A Pandemic

April 6, 2020 by 3 Comments

At this point, most of us are painfully aware of the restrictions that COVID-19 social distancing protocols have put on our daily lives. Anyone who can is working from home, major events are canceled, non-essential businesses are closed, and travel is either strongly discouraged or prohibited outright. In particularly hard hit areas, life and commerce has nearly ground to a halt with no clear end date in sight.

Naturally, there are far reaching consequences for this shutdown beyond what’s happening on the individual level. Large scale projects are also being slowed or halted entirely, as there’s only so much you can do remotely. That’s especially true when the assembly of hardware is concerned, which has put some industries in a particularly tight spot. One sector that’s really feeling the strain is aerospace. Around the world, space agencies are finding that their best laid plans are suddenly falling apart in the face of COVID-19.

In some cases it’s a minor annoyance, requiring nothing more than some tweaks to procedures. But when the movements of the planets are concerned, a delay of weeks or months changes everything. While things are still changing too rapidly to make an exhaustive list, we already know of a few missions that are being impacted in these uncertain times.

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Interplanetary Whack-A-Mole: NASA’s High-Stakes Rescue Plan For InSight Lander’s Science Mission

March 12, 2020 by 55 Comments

People rightly marvel at modern surgical techniques that let surgeons leverage the power of robotics to repair the smallest structures in the human body through wounds that can be closed with a couple of stitches. Such techniques can even be applied remotely, linking surgeon and robot through a telesurgery link. It can be risky, but it’s often a patient’s only option.

NASA has arrived at a similar inflection point, except that their patient is the Mars InSight lander, and the surgical suite is currently about 58 million kilometers away. The lander’s self-digging “mole” probe needs a little help getting started, so they’re planning a high-stakes rescue attempt that would make the most seasoned telesurgeon blanch: they want to use the lander’s robotic arm to press down on the mole to help it get back on track.

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A Honeycomb Patching Robot Powered By Arduino

March 3, 2020 by 13 Comments

No, it’s not the kind of honeycomb you’re probably thinking of. We’re talking about the lightweight panels commonly used in aerospace applications. Apparently they’re rather prone to dents and other damage during handling, so Boeing teamed up with students from the California State University to come up with a way to automate the time-consuming repair process.

The resulting machine, which you can see in action after the break, is a phenomenal piece of engineering. But more than that, it’s an impressive use of off-the-shelf components. The only thing more fascinating than seeing this robotic machine perform its artful repairs is counting how many of its core components you’ve got laying around the shop.

Built from aluminum extrusion, powered by an Arduino Due, and spinning a Dewalt cut-off tool that looks like it was just picked it up from Home Depot, you could easily source most of the hardware yourself. Assuming you needed to automatically repair aerospace-grade honeycomb panels, anyway.

At the heart of this project is a rotating “turret” that holds all the tools required for the repair. After the turret is homed and the condition of all the cutting tools is verified, a hole is drilled into the top of the damaged cell. A small tool is then carefully angled into the hole (a little trick that is mechanical poetry in motion) to deburr the hole, and a vacuum is used to suck out any of the filings created by the previous operations. Finally a nozzle is moved into position and the void is filled with expanding foam.

Boeing says it takes up to four hours for a human to perform this same repair. Frankly, that seems a little crazy to us. But then again if we were the ones tasked with repairing a structural panel for a communications satellite or aircraft worth hundreds of millions of dollars, we’d probably take our time too. The video is obviously sped up so it’s hard to say exactly how long this automated process takes, but it doesn’t seem like it could be much more than a few minutes from start to finish.

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