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NASA Stennis Takes Key Step in Expanding its Range Operations Work
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By NASA
Teams at NASA’s Michoud Assembly Facility in New Orleans move a liquid hydrogen tank for the agency’s SLS (Space Launch System) rocket into the factory’s final assembly area on April 22, 2025. The propellant tank is one of five major elements that make up the 212-foot-tall rocket stage. NASA/Steven Seipel NASA completed another step to ready its SLS (Space Launch System) rocket for the Artemis III mission as crews at the agency’s Michoud Assembly Facility in New Orleans recently applied a thermal protection system to the core stage’s liquid hydrogen tank.
Building on the crewed Artemis II flight test, Artemis III will add new capabilities with the human landing system and advanced spacesuits to send the first astronauts to explore the lunar South Pole region and prepare humanity to go to Mars. Thermal protection systems are a cornerstone of successful spaceflight endeavors, safeguarding human life, and enabling the launch and controlled return of spacecraft.
The tank is the largest piece of SLS flight hardware insulated at Michoud. The hardware requires thermal protection due to the extreme temperatures during launch and ascent to space – and to keep the liquid hydrogen at minus 423 degrees Fahrenheit on the pad prior to launch.
“The thermal protection system protects the SLS rocket from the heat of launch while also keeping the thousands of gallons of liquid propellant within the core stage’s tanks cold enough. Without the protection, the propellant would boil off too rapidly to replenish before launch,” said Jay Bourgeois, thermal protection system, test, and integration lead at NASA Michoud. “Thermal protection systems are crucial in protecting all the structural components of SLS during launch and flight.”
In February, Michoud crews with NASA and Boeing, the SLS core stage prime contractor, completed the thermal protection system on the external structure of the rocket’s liquid hydrogen propellant fuel tank, using a robotic tool in what is now the largest single application in spaceflight history. The robotically controlled operation coated the tank with spray-on foam insulation, distributing 107 feet of the foam to the tank in 102 minutes. When the foam is applied to the core stage, it gives the rocket a canary yellow color. The Sun’s ultraviolet rays naturally “tan” the thermal protection, giving the SLS core stage its signature orange color, like the space shuttle external tank.
Having recently completed application of the thermal protection system, teams will now continue outfitting the 130-foot-tall liquid hydrogen tank with critical systems to ready it for its designated Artemis III mission. The core stage of SLS is the largest ever built by length and volume, and was manufactured at Michoud using state-of-the-art manufacturing equipment. (NASA/Steven Seipel) While it might sound like a task similar to applying paint to a house or spraying insulation in an attic, it is a much more complex process. The flexible polyurethane foam had to withstand harsh conditions for application and testing. Additionally, there was a new challenge: spraying the stage horizontally, something never done previously during large foam applications on space shuttle external tanks at Michoud. All large components of space shuttle tanks were in a vertical position when sprayed with automated processes.
Overall, the rocket’s core stage is 212 feet with a diameter of 27.6 feet, the same diameter as the space shuttle’s external tank. The liquid hydrogen and liquid oxygen tanks feed four RS-25 engines for approximately 500 seconds before SLS reaches low Earth orbit and the core stage separates from the upper stage and NASA’s Orion spacecraft.
“Even though it only takes 102 minutes to apply the spray, a lot of careful preparation and planning is put into this process before the actual application of the foam,” said Boeing’s Brian Jeansonne, the integrated product team senior leader for the thermal protection system at NASA Michoud. “There are better process controls in place than we’ve ever had before, and there are specialized production technicians who must have certifications to operate the system. It’s quite an accomplishment and a lot of pride in knowing that we’ve completed this step of the build process.”
The core stage of SLS is the largest NASA has ever built by length and volume, and it was manufactured at Michoud using state-of-the-art manufacturing equipment. Michoud is a unique, advanced manufacturing facility where the agency has built spacecraft components for decades, including the space shuttle’s external tanks and Saturn V rockets for the Apollo program.
Through Artemis, NASA will send astronauts to explore the Moon for scientific discovery, economic benefits, and build the foundation for the first crewed missions to Mars.
For more information on the Artemis Campaign, visit:
https://www.nasa.gov/feature/artemis/
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Jonathan Deal
Marshall Space Flight Center, Huntsville, Ala.
256-544-0034
jonathan.e.deal@nasa.gov
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By NASA
5 min read
Preparations for Next Moonwalk Simulations Underway (and Underwater)
ICON’s next generation Vulcan construction system 3D printing a simulated Mars habitat for NASA’s Crew Health and Performance Exploration Analog (CHAPEA) missions.ICON One of the keys to a sustainable human presence on distant worlds is using local, or in-situ, resources which includes building materials for infrastructure such as habitats, radiation shielding, roads, and rocket launch and landing pads. NASA’s Space Technology Mission Directorate is leveraging its portfolio of programs and industry opportunities to develop in-situ, resource capabilities to help future Moon and Mars explorers build what they need. These technologies have made exciting progress for space applications as well as some impacts right here on Earth.
The Moon to Mars Planetary Autonomous Construction Technology (MMPACT) project, funded by NASA’s Game Changing Development program and managed at the agency’s Marshall Space Flight Center in Huntsville, Alabama, is exploring applications of large-scale, robotic 3D printing technology for construction on other planets. It sounds like the stuff of science fiction, but demonstrations using simulated lunar and Martian surface material, known as regolith, show the concept could become reality.
Lunar 3D printing prototype.Contour Crafting With its partners in industry and academic institutions, MMPACT is developing processing technologies for lunar and Martian construction materials. The binders for these materials, including water, could be extracted from the local regolith to reduce launch mass. The regolith itself is used as the aggregate, or granular material, for these concretes. NASA has evaluated these materials for decades, initially working with large-scale 3D printing pioneer, Dr. Behrokh Khoshnevis, a professor of civil, environmental and astronautical engineering at the University of Southern California in Los Angeles.
Khoshnevis developed techniques for large-scale extraterrestrial 3D printing under the NASA Innovative Advanced Concepts (NIAC) program. One of these processes is Contour Crafting, in which molten regolith and a binding agent are extruded from a nozzle to create infrastructure layer by layer. The process can be used to autonomously build monolithic structures like radiation shielding and rocket landing pads.
Continuing to work with the NIAC program, Khoshnevis also developed a 3D printing method called selective separation sintering, in which heat and pressure are applied to layers of powder to produce metallic, ceramic, or composite objects which could produce small-scale, more-precise hardware. This energy-efficient technique can be used on planetary surfaces as well as in microgravity environments like space stations to produce items including interlocking tiles and replacement parts.
While NASA’s efforts are ultimately aimed at developing technologies capable of building a sustainable human presence on other worlds, Khoshnevis is also setting his sights closer to home. He has created a company called Contour Crafting Corporation that will use 3D printing techniques advanced with NIAC funding to fabricate housing and other infrastructure here on Earth.
Another one of NASA’s partners in additive manufacturing, ICON of Austin, Texas, is doing the same, using 3D printing techniques for home construction on Earth, with robotics, software, and advanced material.
Construction is complete on a 3D-printed, 1,700-square-foot habitat that will simulate the challenges of a mission to Mars at NASA’s Johnson Space Center in Houston, Texas. The habitat will be home to four intrepid crew members for a one-year Crew Health and Performance Analog, or CHAPEA, mission. The first of three missions begins in the summer of 2023. The ICON company was among the participants in NASA’s 3D-Printed Habitat Challenge, which aimed to advance the technology needed to build housing in extraterrestrial environments. In 2021, ICON used its large-scale 3D printing system to build a 1,700 square-foot simulated Martian habitat that includes crew quarters, workstations and common lounge and food preparation areas. This habitat prototype, called Mars Dune Alpha, is part of NASA’s ongoing Crew Health and Performance Exploration Analog, a series of Mars surface mission simulations scheduled through 2026 at NASA’s Johnson Space Center in Houston.
With support from NASA’s Small Business Innovation Research program, ICON is also developing an Olympus construction system, which is designed to use local resources on the Moon and Mars as building materials.
The ICON company uses a robotic 3D printing technique called Laser Vitreous Multi-material Transformation, in which high-powered lasers melt local surface materials, or regolith, that then solidify to form strong, ceramic-like structures. Regolith can similarly be transformed to create infrastructure capable of withstanding environmental hazards like corrosive lunar dust, as well as radiation and temperature extremes.
The company is also characterizing the gravity-dependent properties of simulated lunar regolith in an experiment called Duneflow, which flew aboard a Blue Origin reusable suborbital rocket system through NASA’s Flight Opportunities program in February 2025. During that flight test, the vehicle simulated lunar gravity for approximately two minutes, enabling ICON and researchers from NASA to compare the behavior of simulant against real regolith obtained from the Moon during an Apollo mission.
Learn more: https://www.nasa.gov/space-technology-mission-directorate/
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Last Updated May 13, 2025 EditorLoura Hall Related Terms
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By NASA
4 min read
Preparations for Next Moonwalk Simulations Underway (and Underwater)
The 2025 internship class at NASA’s Armstrong Flight Research Center in Edwards, California, stand in front of the historic X-1E aircraft on display at the center. From left are interns: Tyler Requa, Gokul Nookula, Madeleine Phillips, Oscar Keiloht Chavez Ramirez, and Nicolas Marzocchetti.NASA/Steve Freeman Lee esta historia en español aquí.
Do you dream of working for NASA and contributing to exploration and innovation for the benefit of humanity? The agency’s internship programs provide high school and college students opportunities to advance NASA’s mission in aeronautics, science, technology, and space.
Claudia Sales, Kassidy McLaughlin, and Julio Treviño started their careers as interns at NASA’s Armstrong Flight Research Center in Edwards, California, where they continue to explore the secrets of the universe. Their journeys highlight the long-term impact of the NASA’s science, technology, engineering, and mathematics (STEM) programs.
Claudia Sales, NASA’s acting X-59 deputy chief engineer and airworthiness certification lead for the quiet supersonic research aircraft, supports ground testing for Acoustic Research Measurements (ARM) flights. The test campaign to evaluate technologies that reduce aircraft noise was conducted at NASA’s Armstrong Flight Research Center in Edwards, California, in 2018.NASA/Ken Ulbrich Claudia Sales
“I knew since I was a child that I wanted to work for NASA,” said Claudia Sales, acting X-59 deputy chief engineer X-59 deputy chief engineer and airworthiness certification lead for the agency’s quiet supersonic research aircraft.
Sales’ journey at NASA started in 2005 as a Pathways intern, a NASA work-study (co-op) program. She worked in propulsion and structures branches and supported such projects as the X-43A hypersonic research aircraft (Hyper-X) and the X-37 reusable orbital launch vehicle, where she had the opportunity to perform calculations for thermal estimations and trajectory analyses. She also completed design work with NASA Armstrong’s Experimental Fabrication Shop.
“It had been a dream of mine to be a part of unique, one-of-a-kind flight research projects,” Sales said. “My mentor was amazing at exposing me to a wide variety of experiences and working on something unique to one day be implemented on an air vehicle to make the world a better place.”
Claudia Sales, NASA’s acting X-59 deputy chief engineer and airworthiness certification lead for the quiet supersonic research aircraft, stands in front of a Gulfstream G-III, also known as Subsonic Research Aircraft Testbed (SCRAT). Sales supported ground testing as test conductor for Acoustics Research Measurements (ARM) flights at NASA’s Armstrong Research Flight Center in Edwards, California, in 2018.NASA/Ken Ulbrich NASA’s flight systems engineer, Kassidy Mclaughlin conducts environmental testing on an instrumentation pallet. The pallet was used during NASA’s National Campaign project in 2020 at NASA’s Armstrong Flight Research Center in Edwards, California.NASA/Lauren Hughes Kassidy McLaughlin
Similarly, flight systems engineer Kassidy McLaughlin discovered that mentorship and hands-on experience as an intern were key to her professional development. She currently leads the development of a ground control station at NASA Armstrong.
In high school and college, McLaughlin enrolled in STEM classes, knowing she wanted to pursue a career in engineering. Encouraged by her mother to apply for a NASA internship, McLaughlin’s career began in 2014 as an intern for NASA Armstrong’s Office of STEM Engagement. She later transitioned to the Pathways program.
“My mentor gave me the tools necessary, and encouraged me to ask questions,” McLaughlin said. “He helped show me that I was capable of anything if I set my mind to it.”
During five rotations as an intern, she worked on the Unmanned Aircraft Systems Integration in the National Airspace System (UAS in the NAS) project. “It is such a rewarding feeling to be in a control room when something you have worked on is flying,” McLaughlin said. That experience inspired her to pursue a career in mechanical engineering.
“NASA Armstrong offered something special when it came to the people,” McLaughlin said. “The culture at the center is so friendly and everyone is so welcoming.”
Julio Treviño, lead operations engineer for NASA’s Global Hawk SkyRange project, stands in front of an F/A-18 mission support aircraft at NASA’s Armstrong Flight Research Center in Edwards, California.NASA/Joshua Fisher Julio Treviño
Julio Treviño, lead operations engineer for NASA’s Global Hawk SkyRange project, ensures airworthiness throughout the planning, integration, and flight phases of unique systems and vehicles. He is also a certified mission controller, mission director, and flight test engineer for various agency aircraft.
Much like McLaughlin, Treviño began his journey in 2018 as a Pathway’s intern for the Dynamic and Controls branch at NASA Armstrong. That experience paved the way for success after graduating with a degree in mechanical engineering.
“As an intern, I had the opportunity to work on designing and creating a battery model for an all-electric aircraft,” Treviño said. “It was officially published as a NASA software model for use by anyone throughout the agency.”
Treviño also credits NASA’s culture and people as the best part of his internship. “I had very supportive mentors throughout my time as an intern and the fact that everyone here genuinely loves the work that they do is awesome,” he said.
2025 Application Deadlines
Every year, NASA provides more than 2,000 students the opportunity to impact the agency’s mission through hands-on internships. The 2025 application for fall is May 16, 2025.
To learn more about NASA’s internship programs, application deadlines, and eligibility, visit https://www.nasa.gov/learning-resources/internship-programs/
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Last Updated May 12, 2025 EditorDede DiniusContactPriscila Valdezpriscila.valdez@nasa.govLocationArmstrong Flight Research Center Related Terms
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By Space Force
U.S. Space Force Chief of Space Operations Gen. Chance Saltzman emphasized the critical role of partnerships and the growing strategic importance of space during his remarks at the 2nd International AeroSpace Power Conference in Rome.
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By NASA
5 min read
Preparations for Next Moonwalk Simulations Underway (and Underwater)
Editor’s Note: The following is one of three related articles about the NASA Data Acquisition System and related efforts. Please visit Stennis News – NASA to access accompanying articles.
A blended team of NASA personnel and contractors support ongoing development and operation of the NASA Data Acquisition System at NASA’s Stennis Space Center. Team members include, left to right: Andrew Graves (NASA), Shane Cravens (Syncom Space Services), Peggi Marshall (Syncom Space Services), Nicholas Payton Karno (Syncom Space Services), Alex Elliot (NASA), Kris Mobbs (NASA), Brandon Carver (NASA), Richard Smith (Syncom Space Services), and David Carver (NASA)NASA/Danny Nowlin Members of the NASA Data Acquisition System team at NASA’s Stennis Space Center evaluate system hardware for use in monitoring and collecting propulsion test data at the site.NASA/Danny Nowlin NASA software engineer Alex Elliot, right, and Syncom Space Services software engineer Peggi Marshall fine-tune data acquisition equipment at NASA’s Stennis Space Center by adjusting an oscilloscope to capture precise measurements. NASA/Danny Nowlin Syncom Space Services software test engineer Nicholas Payton Karno monitors a lab console at NASA’s Stennis Space Center displaying video footage of an RS-25 engine gimbal test, alongside data acquisition screens showing lab measurements. NASA/Danny Nowlin Just as a steady heartbeat is critical to staying alive, propulsion test data is vital to ensure engines and systems perform flawlessly.
The accuracy of the data produced during hot fire tests at NASA’s Stennis Space Center near Bay St. Louis, Mississippi, tells the performance story.
So, when NASA needed a standardized way to collect hot fire data across test facilities, an onsite team created an adaptable software tool to do it.
“The NASA Data Acquisition System (NDAS) developed at NASA Stennis is a forward-thinking solution,” said David Carver, acting chief of the Office of Test Data and Information Management. “It has unified NASA’s rocket propulsion testing under an adaptable software suite to meet needs with room for future expansion, both within NASA and potentially beyond.”
Before NDAS, contractors conducting test projects used various proprietary tools to gather performance data, which made cross-collaboration difficult. NDAS takes a one-size-fits-all approach, providing NASA with its own system to ensure consistency.
“Test teams in the past had to develop their own software tools, but now, they can focus on propulsion testing while the NDAS team focuses on developing the software that collects data,” said Carver.
A more efficient workflow has followed since the software system is designed to work with any test hardware. It allows engineers to seamlessly work between test areas, even when upgrades have been made and hardware has changed, to support hot fire requirements for the agency and commercial customers.
With the backing and resources of the NASA Rocket Propulsion Test (RPT) Program Office, a blended team of NASA personnel and contractors began developing NDAS in 2011 as part of the agency’s move to resume control of test operations at NASA Stennis. Commercial entities had conducted the operations on NASA’s behalf for several decades.
The NASA Stennis team wrote the NDAS software code with modular components that function independently and can be updated to meet the needs of each test facility. The team used LabVIEW, a graphical platform that allows developers to build software visually rather than using traditional text-based code.
Syncom Space Services software engineer Richard Smith, front, analyzes test results using the NASA Data Acquisition System Displays interface at NASA’s Stennis Space Center while NASA software engineer Brandon Carver actively tests and develops laboratory equipment. NASA/Danny Nowlin NASA engineers, from left to right, Tristan Mooney, Steven Helmstetter Chase Aubry, and Christoffer Barnett-Woods are shown in the E-1 Test Control Center where the NASA Data Acquisition System is utilized for propulsion test activities. NASA/Danny Nowlin NASA engineers Steven Helmstetter, Christoffer Barnett-Woods, and Tristan Mooney perform checkouts on a large data acquisition system for the E-1 Test Stand at NASA’s Stennis Space Center. The data acquisition hardware, which supports testing for E Test Complex commercial customers, is controlled by NASA Data Acquisition System software that allows engineers to view real-time data while troubleshooting hardware configuration.NASA/Danny Nowlin NASA engineers Steven Helmstetter, left, and Tristan Mooney work with the NASA Data Acquisition System in the E-1 Test Control Center, where the system is utilized for propulsion test activities.NASA/Danny Nowlin “These were very good decisions by the original team looking toward the future,” said Joe Lacher, a previous NASA project manager. “LabVIEW was a new language and is now taught in colleges and widely used in industry. Making the program modular made it adaptable.”
During propulsion tests, the NDAS system captures both high-speed and low-speed sensor data. The raw sensor data is converted into units for both real-time monitoring and post-test analysis.
During non-test operations, the system monitors the facility and test article systems to help ensure the general health and safety of the facility and personnel.
“Having quality software for instrumentation and data recording systems is critical and, in recent years, has become increasingly important,” said Tristan Mooney, NASA instrumentation engineer. “Long ago, the systems used less software, or even none at all. Amplifiers were configured with physical knobs, and data was recorded on tape or paper charts. Today, we use computers to configure, display, and store data for nearly everything.”
Developers demonstrated the new system on the A-2 Test Stand in 2014 for the J-2X engine test project.
From there, the team rolled it out on the Fred Haise Test Stand (formerly A-1), where it has been used for RS-25 engine testing since 2015. A year later, teams used NDAS on the Thad Cochran Test Stand (formerly B-2) in 2016 to support SLS (Space Launch System) Green Run testing for future Artemis missions.
One of the project goals for the system is to provide a common user experience to drive consistency across test complexes and centers.
Kris Mobbs, current NASA project manager for NDAS, said the system “really shined” during the core stage testing. “We ran 24-hour shifts, so we had people from across the test complex working on Green Run,” Mobbs said. “When the different shifts came to work, there was not a big transition needed. Using the software for troubleshooting, getting access to views, and seeing the measurements were very common activities, so the various teams did not have a lot of build-up time to support that test.”
Following success at the larger test stands, teams started using NDAS in the E Test Complex in 2017, first at the E-2 Test Stand, then on the E-1 and E-3 stands in 2020.
Growth of the project was “a little overwhelming,” Lacher recalled. The team maintained the software on active stands supporting tests, while also continuing to develop the software for other areas and their many unique requirements.
Each request for change had to be tracked, implemented into the code, tested in the lab, then deployed and validated on the test stands.
“This confluence of requirements tested my knowledge of every stand and its uniqueness,” said Lacher. “I had to understand the need, the effort to meet it, and then had to make decisions as to the priorities the team would work on first.”
Creation of the data system and its ongoing updates have transformed into opportunities for growth among the NASA Stennis teams working together.
“From a mechanical test operations perspective, NDAS has been a pretty easy system to learn,” said Derek Zacher, NASA test operations engineer. “The developers are responsive to the team’s ideas for improvement, and our experience has consistently improved with the changes that enable us to view our data in new ways.”
Originally designed to support the RPT office at NASA Stennis, the software is expanding beyond south Mississippi to other test centers, attracting interest from various NASA programs and projects, and garnering attention from government agencies that require reliable and scalable data acquisition. “It can be adopted nearly anywhere, such as aerospace and defense, research and development institutions and more places, where data acquisition systems are needed,” said Mobbs. “It is an ever-evolving solution.”
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Last Updated May 08, 2025 EditorNASA Stennis CommunicationsContactC. Lacy Thompsoncalvin.l.thompson@nasa.gov / (228) 688-3333LocationStennis Space Center Related Terms
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