Mary Sherman Morgan, Rocket Fuel Mixologist

July 2, 2019 by 52 Comments

In the fall of 1957, it seemed as though the United States’ space program would never get off the ground. The USSR had launched Sputnik in October, and this cemented their place in history as the first nation in space. If that weren’t bad enough, they put Sputnik 2 into orbit a month later.

By Christmas, things looked even worse. The US had twice tried to launch Navy-designed Vanguard rockets, and both were spectacular failures. It was time to use their ace in the hole: the Redstone rocket, a direct descendant of the V-2s designed during WWII. The only problem was the propellant. It would never get the payload into orbit as-is.

The US Army awarded a contract to North American Aviation (NAA) to find a propellant that would do the job. But there was a catch: it was too late to make any changes to the engine’s design, so they had to work with big limitations. Oh, and the Army needed it two days before yesterday.

The Army sent a Colonel to NAA to deliver the contract, and to personally insist that they put their very best man on the job. And they did. What the Army didn’t count on was that NAA’s best man was actually a woman with no college degree.

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NASA’s “Green” Fuel Seeks Safer Spaceflight By Finally Moving Off Toxic Hydrazine

July 1, 2019 by 35 Comments

Spaceflight is inherently dangerous. It takes a certain type of person to willingly strap into what’s essentially a refined bomb and hope for the best. But what might not be so obvious is that the risks involved aren’t limited to those who are personally making the trip. The construction and testing of space-bound vehicles poses just as much danger to engineers here on the ground as it does to the astronauts in orbit. Arguably, more so. Far more individuals have given their lives developing rocket technology than have ever died in the cockpit of one of them.

Reddish brown exhaust of hydrazine thrusters

Ultimately, this is because of the enormous amount of energy stored in the propellants required to make a rocket fly. Ground support personnel need to exercise great care even when dealing with “safe” propellants, such as the classic combination of kerosene and liquid oxygen. On the other end of the spectrum you have chemicals that are so unstable and toxic that they can’t be handled without special training and equipment.

One of the most dangerous chemicals ever used in rocket propulsion is hydrazine; and yet from the Second World War to the present day, it’s been considered something of an occupational hazard of spaceflight. While American launch vehicles largely moved away from using it as a primary propellant, hydrazine is still commonly used for smaller thrusters on spacecraft.

When SpaceX’s Crew Dragon exploded in April during ground tests, the release of approximately one and a half tons of hydrazine and nitrogen tetroxide propellants required an environmental cleanup at the site.

But soon, that might change. NASA has been working on a project they call the Green Propellant Infusion Mission (GPIM) which is specifically designed to reduce modern spacecraft’s dependency on hydrazine. In collaboration with the Air Force Research Laboratory at California’s Edwards Air Force Base, the space agency has spearheaded the development of a new propellant that promises to not just replace hydrazine, but in some scenarios even outperform it.

So what’s so good about this new wonder fuel, called AF-M315E? To really understand why NASA is so eager to power future craft with something new, we first have to look at the situation we’re in currently.

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These Projects Bent Over Backward To Win The Flexible PCB Contest

June 19, 2019 by 7 Comments

Back in March, the call went out: take your wiggliest, floppiest, most dimensionally compliant idea, and show us how it would be better if only you could design it around a flexible PCB. We weren’t even looking for a prototype; all we needed was an idea with perhaps a sketch, even one jotted on the legendary envelope or cocktail napkin.

When we remove constraints like that, it’s interesting to see how people respond. We have to say that the breadth of applications for flex PCBs and the creativity shown in designing them into projects was incredible. We saw everything from circuit sculpture to wearables. Some were strictly utilitarian and others were far more creative. In the end we got 70 entries, and with 60 prizes to be awarded, the odds were ever in your favor.

Now that the entries have been evaluated and the winners decided, it’s time to look over the ways you came up with to put a flexible PCB to work. Normally we list all the winners in our contest wrap-ups, but with so many winners we can’t feature everyone. We’ll just call out a few of the real standout projects here, but you really should check the list of winning projects to see the full range of what this call for flexibility brought out in our community.

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Everything We Know About SpaceX’s Starlink Network

May 20, 2019 by 75 Comments

When it comes to SpaceX, or perhaps more accurately its somewhat eccentric founder and CEO Elon Musk, it can be difficult to separate fact from fiction. For as many incredible successes SpaceX has had, there’s an equal number of projects or ideas which get quietly delayed or shelved entirely once it becomes clear the technical challenges are greater than anticipated. There’s also Elon’s particular brand of humor to contend with; most people assumed his claim that the first Falcon Heavy payload would be his own personal Tesla Roadster was a joke until he Tweeted the first shots of it being installed inside the rocket’s fairing.

So a few years ago when Elon first mentioned Starlink, SpaceX’s plan for providing worldwide high-speed Internet access via a mega-constellation of as many as 12,000 individual satellites, it’s no surprise that many met the claims with a healthy dose of skepticism. The profitability of Starlink was intrinsically linked to SpaceX’s ability to substantially lower the cost of getting to orbit through reusable launch vehicles, a capability the company had yet to successfully demonstrate. It seemed like a classic cart before the horse scenario.

But today, not only has SpaceX begun regularly reusing the latest version of their Falcon 9 rocket, but Starlink satellites will soon be in orbit around the Earth. They’re early prototypes that aren’t as capable as the final production versions, and with only 60 of them on the first launch it’s still a far cry from thousands of satellites which would be required for the system to reach operational status, but there’s no question they’re real.

During a media call on May 15th, Elon Musk let slip more technical information about the Starlink satellites than we’ve ever had before, giving us the first solid details on the satellites themselves, what the company’s goals are, and even a rough idea when the network might become operational.

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Lockheed Wants To Build The Next Lunar Lander

April 29, 2019 by 39 Comments

The United States is going back to the moon, and it’s happening sooner than you would think. NASA is going back to the moon in 2024, and they might just have the support of Congress to do so.

Getting to the moon is one thing, and since SpaceX launched a car to the asteroid belt, this future of boots on the moon after Apollo seems closer than ever before. But what about landing on the moon? There’s only ever been one Lunar Lander that has taken people down to the moon and brought them back again, and it’s doubtful that design will be used again. Now, Lockheed has their own plan for landing people on the moon, and they might be able to do it by 2024.

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Why Satellites Of The Future Will Be Built To Burn

April 22, 2019 by 33 Comments

There’s no shortage of ways a satellite in low Earth orbit can fail during the course of its mission. Even in the best case scenario, the craft needs to survive bombardment by cosmic rays and tremendous temperature variations. To have even a chance of surviving the worst, such as a hardware fault or collision with a rogue piece of space garbage, it needs to be designed with robust redundancies which can keep everything running in the face of systemic damage. Of course, before any of that can even happen it will need to survive the wild ride to space; so add high-G loads and intense vibrations to the list of things which can kill your expensive bird.

After all the meticulous engineering and expense involved in putting a satellite into orbit, you might think it would get a hero’s welcome at the end of its mission. But in fact, it’s quite the opposite. The great irony is that after all the time and effort it takes to develop a spacecraft capable of surviving the rigors of spaceflight, in the end, its operators will more than likely command the craft to destroy itself by dipping its orbit down into the Earth’s atmosphere. The final act of a properly designed satellite will likely be to commit itself to the same fiery fate it had spent years or even decades avoiding.

You might be wondering how engineers design a spacecraft that is simultaneously robust enough to survive years in the space environment while at the same time remaining just fragile enough that it completely burns up during reentry. Up until fairly recently, the simple answer is that it wasn’t really something that was taken into account. But with falling launch prices promising to make space a lot busier in the next few years, the race is on to develop new technologies which will help make sure that a satellite is only intact for as long as it needs to be.

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Schrödinger Quantum Percolator Makes Half Decent Coffee

April 1, 2019 by 34 Comments

I couldn’t decide between normal and decaffeinated coffee. So to eliminate delays in my morning routine, and decision fatigue,  I’ve designed the Schrödinger Quantum Percolator — making the state of my coffee formally undecidable until I drink it.

At its core, the Quantum Percolator contains a novel quantum event detector that uses electron tunneling to determine whether to use caffeinated or decaffeinated coffee. The mechanical components are enclosed in an opaque box, so I can’t tell which type of coffee is being used.

The result is coffee that simultaneously contains and does not contain caffeine – at least until you collapse the caffeination probability waveform by drinking it. As the expression goes, you can’t have your quantum superposition of states and drink it too!

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