2020: As The Hardware World Turns

December 29, 2020 by Tom Nardi 13 Comments

By pretty much any metric you care to use, 2020 has been an unforgettable year. Usually that would be a positive thing, but this time around it’s a bit more complicated. The global pandemic, unprecedented in modern times, impacted the way we work, learn, and gather. Some will look back on their time in lockdown as productive, if a bit lonely. Other’s have had their entire way of life uprooted, with no indication as to when or if things will ever return to normal. Whatever “normal” is at this point.

But even in the face of such adversity, there have been bright spots for our community. With traditional gatherings out of the question, many long-running tech conferences moved over to a virtual format that allowed a larger and more diverse array of presenters and attendees than would have been possible in the past. We also saw hackers and makers all over the planet devote their skills and tools to the production of personal protective equipment (PPE). In a turn of events few could have predicted, the 2020 COVID-19 pandemic helped demonstrate the validity of hyperlocal manufacturing in a way that’s never happened before.

For better or for worse, most of us will associate 2020 with COVID-19 for the rest of our lives. Really, how could we not? But over these last twelve months we’ve borne witness to plenty of stories that are just as deserving of a spot in our collective memories. As we approach the twilight hours of this most ponderous year, let’s take a look back at some of the most interesting themes that touched our little corner of the tech world this year.

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Adding Space Music To The Astronomy Toolbox

December 22, 2020 by Roger Cheng 4 Comments

Astronomy fans were recently treated to the Great Conjunction, where Jupiter and Saturn appear close together from the perspective of our planet Earth. Astronomy has given us this and many other magnificent sights, but we can get other senses involved. Science News tells of explorations into adapting our sense of hearing into tools of astronomical data analysis.

Data visualization has long been a part of astronomy, but they’re not restricted to charts and graphs that require a trained background to interpret. Every “image” generated using data from radio telescopes (like the recently-lost Arecibo facility) are a visualization of data from outside the visible spectrum. Visualizations also include crowd pleasing false-color images such as The Pillars of Creation published by NASA where interstellar emissions captured by science instruments are remapped to colors in the visible spectrum. The results are equal parts art and science, and can be appreciated from either perspective.

Data sonification is a whole other toolset with different strengths. Our visual system evolved ability to pick out edges and patterns in spatial plots, which we exploit for data visualization. In contrast our aural system evolved ability to process data in the frequency domain, and the challenge is to figure out how to use those abilities to gain scientifically relevant data insight. For now this field of work is more art than science, but it does open another venue for the visually impaired. Some of whom are already active contributors in astronomy and interested in applying their well-developed sense of hearing to their work.

Of course there’s no reason this has to be restricted to astronomy. A few months ago we covered a project for sonification of DNA data. It doesn’t take much to get started, as shown in this student sonification project. We certainly have no shortage of projects that make interesting sounds on this site, perhaps one of them will be the key.

The Cost Of Moving Atoms In Space; Unpacking The Dubious Claims Of A $10 Quintillion Space Asteroid

November 23, 2020 by Bob Baddeley 42 Comments

The rest of the media were reporting on an asteroid named 16 Psyche last month worth $10 quintillion. Oddly enough they reported in July 2019 and again in February 2018 that the same asteroid was worth $700 quintillion, so it seems the space rock market is similar to cryptocurrency in its wild speculation. Those numbers are ridiculous, but it had us thinking about the economies of space transportation, and what atoms are worth based on where they are. Let’s break down how gravity wells, distance, and arbitrage work to figure out how much of this $10-$700 quintillion we can leverage for ourselves.

The value assigned to everything has to do with where a thing is, AND how much someone needs that thing to be somewhere else. If they need it in a different place, someone must pay for the transportation of it.

In international (and interplanetary) trade, this is where Incoterms come in. These are the terms used to describe who pays for and has responsibility for the goods between where they are and where they need to be. In this case, all those materials are sitting on an asteroid, and someone has to pay for all the transport and insurance and duties. Note that on the asteroid these materials need to be mined and refined as well; they’re not just sitting in a box on some space dock. On the other end of the spectrum, order something from Amazon and it’s Amazon that takes care of everything until it’s dropped on your doorstep. The buyer is paying for shipping either way; it’s just a matter of whether that cost is built into the price or handled separately. Another important term is arbitrage, which is the practice of taking a thing from one market and selling it in a different market at a higher price. In this case the two markets are Earth and space.

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Sending 3D Printed Parts To Mars: A Look Inside JPL’s Additive Manufacturing Center

November 10, 2020 by Dan Maloney 5 Comments

With the Mars 2020 mission now past the halfway point between Earth and its destination, NASA’s Jet Propulsion Lab recently released a couple of stories about the 3D-printed parts that made it aboard the Perseverance rover. Tucked into its aeroshell and ready for its high-stakes ride to the Martian surface, Perseverance sports eleven separate parts that we created with additive manufacturing. It’s not the first time a spacecraft has flown with parts made with additive manufacturing technique, but it is the first time JPL has created a vehicle with so many printed parts.

To take a closer look at what 3D-printing for spaceflight-qualified components looks like, and to probe a little into the rationale for additive versus traditional subtractive manufacturing techniques, I reached out to JPL and was put in touch with Andre Pate, Additive Manufacturing Group Lead, and Michael Schein, lead engineer on one of the mission’s main scientific instruments. They both graciously gave me time to ask questions and geek out on all the cool stuff going on at JPL in terms of additive manufacturing, and to find out what the future holds for 3D-printing and spaceflight.

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A Look Behind The “Big Boards” At Mission Control In The Golden Age Of NASA

October 29, 2020 by Dan Maloney 18 Comments

Certified space-nerd and all-around retro-tech guru [Fran Blanche] has just outdone herself with a comprehensive look at how NASA ran the Mission Control “Big Boards” that provided flight data for controllers for Apollo and for the next 20 years of manned spaceflight.

We’ve got to admit, [Fran] surprised us with this one. We had always assumed that the graphs and plots displayed in front of the rows of mint-green consoles and their skinny-tie wearing engineers were video projections using eidophor projectors. And to be sure, an eidophor, the tech of which [Jenny] profiled a while back, was used on one of the screens to feed video into Mission Control, either live from the Moon or from coverage of the launch and recovery operations. But even a cursory glance at the other screens in front of “The Pit” shows projections of a crispness and clarity that was far beyond what 1960s video could achieve.

Instead, plots and diagrams were projected into the rear of the massive screens using a completely electromechanical system. Glass and metal stencils were used to project the icons, maps, and grids, building up images layer by layer. Colors for each layer were obtained by the use of dichroic filters, and icons were physically moved to achieve animations. Graphs and plots were created Etch-a-Sketch style, with a servo-controlled stylus cutting through slides made opaque with a thin layer of metal. The whole thing is wonderfully complex, completely hacky, and a great example of engineering around the limits of technology.

Hats off to [Fran] for digging into this forgotten bit of Space Race tech. Seeing something like this makes the Mission Control centers of today look downright boring by comparison.

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Bringing High Temperature 3D Printing To The Masses

October 28, 2020 by Tom Nardi 77 Comments

Despite the impressive variety of thermoplastics that can be printed on consumer-level desktop 3D printers, the most commonly used filament is polylactic acid (PLA). That’s because it’s not only the cheapest material available, but also the easiest to work with. PLA can be extruded at temperatures as low as 180 °C, and it’s possible to get good results even without a heated bed. The downside is that objects printed in PLA tend to be somewhat brittle and have a low heat tolerance. It’s a fine plastic for prototyping and light duty projects, but it won’t take long for many users to outgrow its capabilities.

The next step up is usually polyethylene terephthalate glycol (PETG). This material isn’t much more difficult to work with than PLA, but is more durable, can handle higher temperatures, and in general is better suited for mechanical parts. If you need greater durability or higher heat tolerance than PETG offers, you could move on to something like acrylonitrile butadiene styrene (ABS), polycarbonate (PC), or nylon. But this is where things start to get tricky. Not only are the extrusion temperatures of these materials greater than 250 °C, but an enclosed print chamber is generally recommended for best results. That puts them on the upper end of what the hobbyist community is generally capable of working with.

Industrial 3D printers like the Apium P220 start at $30,000.

But high-end industrial 3D printers can use even stronger plastics such as polyetherimide (PEI) or members of the polyaryletherketone family (PAEK, PEEK, PEKK). Parts made from these materials are especially desirable for aerospace applications, as they can replace metal components while being substantially lighter.

These plastics must be extruded at temperatures approaching 400 °C, and a sealed build chamber kept at >100 °C for the duration of the print is an absolute necessity. The purchase price for a commercial printer with these capabilities is in the tens of thousands even on the low end, with some models priced well into the six figure range.

Of course there was a time, not quite so long ago, where the same could have been said of 3D printers in general. Machines that were once the sole domain of exceptionally well funded R&D labs now sit on the workbenches of hackers and makers all over the world. While it’s hard to say if we’ll see the same race to the bottom for high temperature 3D printers, the first steps towards democratizing the technology are already being made.

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Engine Trouble Delays SpaceX’s Return To The ISS

October 27, 2020 by Tom Nardi 20 Comments

A crewed mission to the International Space Station that was set to depart from Kennedy Space Center on Halloween has been pushed back at least several weeks as NASA and SpaceX investigate an issue with the company’s Merlin rocket engine. But the problem in question wasn’t actually discovered on the booster that’s slated to carry the four new crew members up to the orbiting outpost. This story starts back on October 2nd, when the computer aboard a Falcon 9 set to carry a next-generation GPS III satellite into orbit for the US Space Force shut down the engines with just two seconds to go before liftoff.

The fact that SpaceX and NASA have decided to push back the launch of a different Falcon 9 is a clear indication that the issue isn’t limited to just one specific booster, and must be a problem with the design or construction of the Merlin engine itself. While both entities have been relatively tight lipped about the current situation, a Tweet from CEO Elon Musk made just hours after the GPS III abort hinted the problem was with the engine’s gas generator:

As we’ve discussed previously, the Merlin is what’s known as an “open cycle” rocket engine. In this classical design, which dates back to the German V-2 of WWII, the exhaust from what’s essentially a smaller and less efficient rocket engine is used to spin a turbine and generate the power required to pump the propellants into the main combustion chamber. Higher than expected pressure in the gas generator could lead to a catastrophic failure of the turbine it drives, so it’s no surprise that the Falcon 9’s onboard systems determined an abort was in order.

Grounding an entire fleet of rockets because a potentially serious fault has been discovered in one of them is a rational precaution, and has been done many times before. Engineers need time to investigate the issue and determine if changes must be made on the rest of the vehicles before they can safely return to flight. But that’s where things get interesting in this case.

SpaceX hasn’t grounded their entire fleet of Falcon 9 rockets. In fact, the company has flown several of them since the October 2nd launch abort. So why are only some of these boosters stuck in their hangers, while others are continuing to fly their scheduled missions?

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