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The thermal protection and passive thermal system Technical Discipline Leads (TDL) at the Johnson Space Center are in need of a visual aide and short concept demonstration animation that shows a new automated manufacturing process, using robotic additive manufacturing methods, being pursued for development as part of the effort to address the existing technical gaps for future human exploration missions.
The 3D rendering of the envisioned concept, with short animations showing the printing process of a spacecraft thermal protection heat shield and pressure vessel (see guidance below), will help the TDL’s convey the ideas to NASA management, universities and private companies for funding and partnership opportunities in this development endeavor.
JUDGING CRITERIA
1. The graphics and animation should depict a modern automated manufacturing site in which large space structures, note dimensions in above sketches, are being fabricated and covered with thermal protection materials. The materials would be deposited on the structures using additive manufacturing deposition techniques.
2. The artistic concept should be original and not copying the robots shown in the Partner Space. Orion structural images found in the internet can be used as guidance and included in the project. Other vehicle concept could be used but should be submitted for approval by the TDLs before they are included in the work.
3. The rendering must have a realistic appearance with the proper scaling and the space structures depicted are not limited to those in the Partner Space.
TECHNICAL REQUIREMENTS
The process should show two robotic arms performing the printing and final machining of the thermal protection system material.
A feed-bay where multiple printing heads reside should be considered as part of the CAD.
The CAD must show some form of material storage (mixing tank) or filament feed system for the printing process.
The process should show the deposition on a composite material structure for the thermal protection system printing.
There must be a separate CAD showing the 3D printing of a metal spacecraft pressure vessel structure.
SUBMISSION FILE FORMATS
CAD files in STL, STEP
Animation in COLLADA and FBX
ENTERING THE COMPETITION
The Challenge is open to everyone except employees and families of GrabCAD and the Sponsor. Multiple entries are welcome. Team entries are welcome.
By entering the Challenge you:
1. Accept the official GrabCAD Challenges Terms & Conditions.
2. Agree to be bound by the decisions of the judges (Jury).
3. Warrant that you are eligible to participate.
4. Warrant that the submission is your original work.
5. Warrant, to the best of your knowledge, your work is not, and has not been in production or otherwise previously published or exhibited.
6. Warrant neither the work nor its use infringes the intellectual property rights (whether a patent, utility model, functional design right, aesthetic design right, trademark, copyright or any other intellectual property right) of any other person.
7. Warrant participation shall not constitute employment, assignment or offer of employment or assignment.
8. Are not entitled to any compensation or reimbursement for any costs.
9. Agree the Sponsor and GrabCAD have the right to promote all entries.
If you think an entry may infringe on existing copyrighted materials, please email challenges@grabcad.com.
SUBMITTING AN ENTRY
Only entries uploaded to GrabCAD through the "Submit entry" button on this Challenge page will be considered an entry. Only public entries are eligible. We encourage teams to use GrabCAD Workbench for developing their entries. Entries are automatically given the tag "nasaprintanimation" when uploading to GrabCAD. Please do not edit or delete this tag. Only entries with valid tag will participate in the Challenge.
AWARDING THE WINNERS
The sum of the Awards is the total gross amount of the reward. The awarded participant is solely liable for the payment of all taxes, duties and other similar measures if imposed on the reward pursuant to the legislation of the country of his/her residence, domicile, citizenship, workplace, or any other criterion of similar nature. Only 1 award per person. Prizes may not be transferred or exchanged. All winners will be contacted by the GrabCAD staff to get their contact information and any other information needed to get the prize to them. Payment of cash awards is made through PayPal. All team awards will be transferred to the member who entered the Challenge.
We will release the finalists before the announcement of the winners to give the Community an opportunity to share their favorites in the comments, discuss concerns, and allow time for any testing or analysis by the Jury. The Jury will take the feedback into consideration when picking the winners.
Winning designs will be chosen based on the Rules and Requirements.
This Challenge ends on August 24th, 2018 (23:59 EST.) Finalists will be announced on August 31st, 2018 Winners will be announced on September 7th, 2018.
$3000 in Prizes!
$1500
$1000
$500
NASA
The National Aeronautics and Space Administration (NASA) is an independent agency of the executive branch of the United States federal government responsible for the civilian space program, as well as aeronautics and aerospace research.
Randy Lillard
Stan Bouslog
Richard Hagen
Angel AlvarezHave an awesome idea for this competition? Want to win cool prizes? Sign-up now to upload your entries.
If you don't receive the email within an hour (and you've checked your Spam folder), email us as confirmation@grabcad.com.
85 comments
Reza Allahyari almost 7 years ago
Nice challenge.i am in ;)
Azamat Sayapov almost 7 years ago
Which material you want to print with?
How it should be printed?
From NASA site about Orion heat shield :"The titanium truss structure has a composite substrate surrounding it."
How it is possible to print metal on top of composite?
Explain, please, the technology you want to be rendered by participators.
Angel Alvarez almost 7 years ago
Hi Azamat, Notice that there are two materials to be printed, one is the thermal protection material and the second is a metal structure. The thermal protection material to be printed would be a paste like material. It would be similar to a clay or concrete extrusion. The thermal protection paste would be the material to be extruded on a composite structure.
dinesh kumar almost 7 years ago
may you give me any helpful link for better understanding(i.e. software, final rendering, material , printing etc.) ?
Bryce Cahill almost 7 years ago
Where are the sketches mentioned in the challenge?
Angel Alvarez almost 7 years ago
Dinesh, you can use your software of preference as long as you can provide the required files. The rendering and component materials are open to your engineering/artistic judgement.
Angel Alvarez almost 7 years ago
Bryce, I've already informed GrabCAD to upload the missing file.
Roger Couture almost 7 years ago
Animation in Collada and FBX ! Is Solidworks *.avi can be converted to these extensions?
Angel Alvarez almost 7 years ago
Roger-Marie, I think Solidworks visualize has the capability of exporting to *.FBX. Simlabs also has a *.FBX exporter plugin
DINANATH VERMA almost 7 years ago
greetings..if any one complete and wins please share creativity
Truong Chu Manh almost 7 years ago
I'm concerned about other aspects related to shape and complicating structure of future robot.. Could I have more information about that? Thanks
Angel Alvarez almost 7 years ago
Truong, Please see attached sketches.
Edit - Massimo Roggiani almost 7 years ago
Hi boys
Kevin Matson almost 7 years ago
@Angel, where are the sketches that you reference above?
Michael Herbert almost 7 years ago
In the TECHNICAL REQUIREMENTS section, you state "The process should show two robotic arms performing the printing and final machining of the thermal protection system material." please explain what you mean by final machining. Will this be a subtractive process using a cutting bit?
Angel Alvarez almost 7 years ago
Kevin, See the requirements section part #2, link for "Partner space"
Angel Alvarez almost 7 years ago
Michael, after the thermal protection material is deposited some machining will be required to prepare the surface for coating.
Kevin Hirtz almost 7 years ago
Can we have more details than a side view of the surface to print on ?
Angel Alvarez almost 7 years ago
This comment was removed
Michael Herbert almost 7 years ago
Just so I understand correctly, you want to 1) 3d print the entire Orion pressure vessel out of metal ?!, 2) 3d print/extrude a thermal paste onto the bottom of two different vehicles to act as a heat shield, and 3) do some final machining to the thermal protection material with a robotic arm in preparation for surface coating.?
sayeem almost 7 years ago
please provide some guide line about the project and how many axis should be arm have should be 6 or 3 axis and degree of freedom
Angel Alvarez almost 7 years ago
Michael, in #2 we only require the CAD for the printing of the Thermal Protection System (TPS) for one vehicle. Correct in 2 and 3
Angel Alvarez almost 7 years ago
Sayeem, there are no requirements for the robot arm, it just needs to be feasible. See requirements section and comments for additional information.
Atom Industries almost 7 years ago
i can take the desing of the robotic arm from the step files of manufacturer page or i need make the robotc arm?
Lat almost 7 years ago
Sorry, This seems some kind of animation project? What's the role of CAD in it ?
Florian Jans almost 7 years ago
A bit disappointed by this challenge. Grab Cad challenges usually ask the community to design new products and develop new concepts and ideas.
Here, it looks more like a "low cost" (compared to what it would cost if asked to a dedicated firm) rendering project.
Flaviano Crespi almost 7 years ago
It seems to me that this challenge is too near at pure sci-fi fantasy
like those launched by the site "launchfort / NASA."
It is therefore a matter for creative graphic designers.
The engineering approach is a bit too far from what you ask for...
Tommy Mueller almost 7 years ago
What a cool challenge! Just started yesterday and I'm onto a pretty good idea and hope to get a WIP up early tomorrow which I’ll add to over the course of the challenge.
The challenge does have a lot of hidden facets and is a bit under documented technically and visually, so I'll be sure to share my 3D and my plan for creating these animations, and maybe it could help others looking for a direction, or to enhance their own concept.
I will share that I’m creating ALL of my 3D using SolidWorks CAD, and will either render/animate this in Modo, or the Unreal Engine. The challenge definitely belongs here on GrabCAD, but you’ll have really to s-t-r-e-t-c-h yourself to round up these project goals if you only have a few disciplines in 3D, or only use to create just the basic products.
Thanks for bringing this to GrabCAD NASA !!
Angel Alvarez almost 7 years ago
Hi Derek, You will find a link labeled “Partner space” under the requirements section. The files under this link will give you an idea on the scale. Note that the Orión heat shield is roughly 16 ft in diameter.
Angel Alvarez almost 7 years ago
Good evening to all. We are glad to see so much interest in this challenge. I will try to address the common questions regarding this challenge. You will find that the challenge is to come up with the CAD of the robotic arms (to protect companies IP this needs to be an original design) and needed equipment for the additive manufacturing process of a human rated spacecraft. Specifically the TPS and pressure vessel portions of the spacecraft. Additional points will be given If a short animation showing the process is provided. NASA is currently engaged in developing this technology for future exploration spacecrafts. Your work will be help us in this effort.
Hartvik Line almost 7 years ago
Wow, this is a very interesting competition, I think it definitely belongs here at GrabCAD. As an engineer, you have to be able to visualize and communicate an idea and consept in different media platforms. I look forward to experiment with rendering animations of CAD models, this is quite new to me as well. But hey, what a great way to learn something new! Good luck everybody
designer mz almost 7 years ago
my name ia manouchehr zarghami im from iran ...
designer mz almost 7 years ago
my love ... my life nasa
Kamen Rusev almost 7 years ago
http://www.spaceflightinsider.com/wp-content/uploads/2015/09/15-182diagram.jpg
Kamen Rusev almost 7 years ago
https://www.youtube.com/watch?time_continue=4&v=4ep8WEQ_tRo
Kesa almost 7 years ago
If you are looking for the concept images, under requirements section above check where it says Partner space in the second paragraph. You click on Partner space and will have the ability to download the images there.
Phil Green almost 7 years ago
@Angel Alvarez in the requirements and also in your response the robotic arms are mentioned. Have robotic arms to be used, or is it possible to work with other "methods" of deposition?
Angel Alvarez almost 7 years ago
Hi Phil, You can proceed with any ideas or concepts you have if they prove to be feasible.
Francisco J. Erenas Rivas almost 7 years ago
Hello,
the ship that we have to deal with the anticaloric coverage, is this?
http://lademajagua.cu/presentan-nave-espacial-para-llevar-personas-a-marte-en-2026/
Angel Alvarez almost 7 years ago
Francisco, the two spacecrafts you can use as guides are the Orion vehicle and the NASA Mid L/D concept (see link provided in the comments section).
Angel Alvarez almost 7 years ago
Tom, We are looking to have a design develop in the next 5 to 10 years.
Francisco J. Erenas Rivas almost 7 years ago
Ok, thank Angel.
NIka Alavidze almost 7 years ago
Is it mandatory to have two, robotic arm?
NIka Alavidze almost 7 years ago
Why there is space vehicle image attached?
Phil Green over 6 years ago
@Tarik
no offense, but dont' you think most of your questions have already been answered?
Marco Boer over 6 years ago
3D printing Starlight :-)
Roger Couture over 6 years ago
You want a giant 3d printer with 6 axes ? :)
Angel Alvarez over 6 years ago
Roger-Marie, big enough to print an Orion heatshield. See attached file in the partner space link.
Angel Alvarez over 6 years ago
Clarification to the community: The proposed design needs to show a system that is capable of printing a human rated spacecraft heatshield and pressure vessel separately (Orion heatshield/pressure vessel preferred). Take a look at file 2.png. As an example, this could be modified to have the robotic arm deposit a slurry to print the heat shield using a rotating table. The design would just modify existing technology (robotic arms or 3d gantries) to accomplish the manufacturing process. A similar and separate configuration could be created for the pressure vessel. Use human rated spacecraft samples (Orion design preferred) that are currently being developed. Avoid the use of futuristic spacecraft designs. Take a close look at the requirements section. Please advise if there is anything missing, or if there are any areas where clarification would be needed. Thank you and good luck to all!
Michael Herbert over 6 years ago
Is MP4 format ok for the animation?
Angel Alvarez over 6 years ago
Hi Tarik, Im not able to access links provided. Let me know if I can answer any questions.
Angel Alvarez over 6 years ago
MP4 would be fine Michael.
smruty swaroop over 6 years ago
Is it possible to extend the deadline?
smruty swaroop over 6 years ago
thank for extending the date of submission.
Tommy Mueller over 6 years ago
Thanks for the time extension!
Shawn Dmello over 6 years ago
Why has the deadline been extended? It isn't fair to people who have worked tirelessly to make sure the model is ready on time. This is really unfair.
Shawn Dmello over 6 years ago
Please revert it back or only extend it by one two days. And if not please take note of the people who have completed the model and animation on time.
smruty swaroop over 6 years ago
reference to help you understand the challenge
Heat shield
SDA - Redesigning the NASA Orion Heat Shield (long version)
https://www.youtube.com/watch?v=gX06h5p__bo
Orion EFT-1 heat shield manufacturing
https://vimeo.com/67660646
Orion EFT-1 heat shield manufacturing
https://vimeo.com/67660646
1000 Seconds to Home: Apollo Heat Shield
https://www.youtube.com/watch?v=64UM3CUqSfg&list=WL&index=139&t=0s
Ingersoll EM-1 aft bulkhead machining b-roll
https://vimeo.com/210658230
Angel Alvarez over 6 years ago
Good afternoon to all,
I wanted to take the opportunity to address concerns regarding the extension of this challenge. We have decided to extend the challenge by 2 weeks in order to allow the opportunity for additional members of the community to submit their proposed designs, and for current participants to make any modifications needed. Without a doubt submissions made by Aug 10th at 11:49pm EST, will be given consideration during the selection process. Please read carefully the requirements and the additional clarifications made in the comments above. The design submitted should show the heat shield portion of the vehicle being printed with the proposed method. The CAD of a partially printed heatshield would help convey the idea of the process. Thank you again for your participation and hard work. Best of luck to all!
Angel Alvarez over 6 years ago
Good afternoon to all,
I wanted to provide additional information related to the heat shield material being developed for this AM process. This material would have a consistency similar to a clay or concrete substrate. I have attached the link below as a reference.
https://www.youtube.com/watch?v=XgPJdpGV8mE
Stan Bouslog over 6 years ago
Folks, I wanted to add to Angel's comments. We are looking for entries that also depict the deposition of thermal protection materials on to the structure. In some cases only the fabrication of the structure is shown.
Tommy Mueller over 6 years ago
I’m working on another entry and I have a few quick questions about the thermal layer:
…
1) About how thick is thermal layer applied? .25-inch, 1-inch, 3-inches? Also, is it traditionally applied as one single layer, or is it comprised of several layers? Or it that up to us?
…
2) What’s the consistency of the thermal material? For example is it nectar-thick, honey-thick, or pudding-thick?
...
Thanks in advance!
Angel Alvarez over 6 years ago
Tommy, You can assume that your heat shield is printed by depositing roughly +/- .5" layers of the ablative material until completing the overall thickness. Currently manufacturing a heat shield involves a 9 step labor intensive process (see second link on @Tarik Cs post) where a honeycomb structure is attached to a titanium base and filled with ablative material. The consistency for the proposed AM process would be similar to the concrete extrusion shown in the YouTube video I posted earlier. I hope this helps.
Tommy Mueller over 6 years ago
Awesome! Thanks!
PAVITAR SINGH©️ over 6 years ago
Can use one robotic arm for manufacturing of heat shield or is it mandatory to use two robotic arms ?
Ralph Zoontjens over 6 years ago
Hi Angel,
I am considering entering this job.
My only question is
Is the honeycomb scaffold absolutely required or are there other possible structural solutions? For example cross-directional 3D printing each subsequent layer and long fiber extrusion.
Best,
Ralph Zoontjens
Product Designer
Angel Alvarez over 6 years ago
Ralph, The honeycomb is used in the current process for structural integrity of the system, but it does not have to be included in the AM process.
Angel Alvarez over 6 years ago
Singh, Two robot arms are suggested unless you are coming up with a gantry system.
PAVITAR SINGH©️ over 6 years ago
Got it sir
PAVITAR SINGH©️ over 6 years ago
Rather than using existing systems like gantry system or other pre existing systems can I introduce new system something innovative system... which will be possible & may be useful...
May be useful for NASA like camera shutter simple mechanism used to grab objects in space.
Video here https://youtu.be/tvyn8dOVGwY
Like this concept of grappler comes from camera shutter
https://youtu.be/qWI_i0QhjzU
So just asking.....
Angel Alvarez over 6 years ago
Try it, as long as you can show that material deposition is possible.
PAVITAR SINGH©️ over 6 years ago
I hope this time, this would be final date,no extension...
PAVITAR SINGH©️ over 6 years ago
. let's break some eggs let's see where I stand... let's learn something new
PAVITAR SINGH©️ over 6 years ago
Hip hop hureeeehhh for NASA.
Angel Alvarez over 6 years ago
Derik, I definitely encourage you to submit your design even if you don't have an animation.
Tommy Mueller over 6 years ago
Good luck everybody!
...
Down to the last ~12 hours!
smruty swaroop over 6 years ago
Thanks grabcad and nasa for amazing challenge.Learned a lots about the orion project.
Tommy Mueller u deserve to win.
PAVITAR SINGH©️ over 6 years ago
CONGRATULATION TO MUELLER...
Tommy Mueller over 6 years ago
Congratulations to the other awesome finalists, and for that matter, all who entered! Lets all hop over to the other NASA challenge now :)
Ronyz Reynald over 6 years ago
The article is okay..https://grabcad.com/challenges/nasa-challenge-human-rated-spacecraft-3d-printing-process-animation
Matt Firmani over 6 years ago
Hey everyone! I'm the Community Support Manager at GrabCAD, and I wanted to let everyone know that our top three winners have been announced! Please join me in congratulating Tommy Mueller, Dario D'Amico, and Ralph Zoontjens on their accomplishment. Thanks to everyone who participated, and we hope to see more from you soon! There's already another NASA challenge underway, and this one awards the top FIVE participants. please check it out:
https://grabcad.com/challenges/nasa-lunar-sampling-system-design-challenge
Tommy Mueller over 6 years ago
I’m overwhelmed, ecstatic, and a bit giddy for this win… but sincerely, there are some terrific designers and engineers that have entered here in this challenge, a lot of hard work from everybody, and I’m very happy to be ranked alongside their amazing skills and talents.
.
Thanks once again to NASA and GrabCAD for putting on this challenge!
Angel Alvarez over 6 years ago
Congratulations to all of you! It was a difficult task to select the winners with so many good submissions. You are an incredibly talented community, and I am looking forward to post more challenges in the near future.
Dario D'Amico over 6 years ago
Thanks to NASA and grabcad for this opportunity. It is an honor to be on the podium of this competition. Congratulations to Tommy for his impressive work.
Ralph Zoontjens over 6 years ago
I am very honored to have won the third place in this challenge. A big thank you to NASA for hosting and congratulations to the other deserved winners! I learned a lot in terms of animation, technology and project planning so am looking forward to joining again in the future.
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