The NASA objective of expanding the human experience into the far reaches of space requires regenerable life support systems. This proposal addresses the fabrication of structured (monolithic),…

This is a $747,990 Small Business Innovation Research (SBIR) Phase II contract awarded by the National Aeronautics and Space Administration (NASA) to Advanced Fuel Research, Inc. (AFR) to develop regenerable life support systems, including structured carbon-based trace contaminant sorbents fabricated using 3D printing. The objective is to create a trace contaminant removal system for the Exploration Portable Life Support System (PLSS) used in extravehicular activities (EVAs) that is rapidly vacuum-regenerable and has weight, size, and power advantages over the current state of the art. This builds on a successful Phase I effort by AFR to demonstrate 3D printing of polymer precursors and carbonization/activation to produce monolithic sorbents with excellent properties. The Phase II work will optimize sorbent performance, design and construct two full-scale prototypes, and provide integration guidelines for the PLSS.

The NASA objective of expanding the human experience into the far reaches of space requires regenerable life support systems. This proposal addresses the fabrication of structured (monolithic), carbon-based trace-contaminant (TC) sorbents for the space suit used in extravehicular activities (evas). The proposed innovations are: (1) the use of thin-walled, structured carbon TC sorbents fabricated using three-dimensional (3D) printing; and (2) the patented low-temperature oxidation step used for the treatment of carbons derived from polymers compatible with 3D printing. The overall objective is to develop a trace-contaminant removal system that is rapidly vacuum-regenerable and that possesses substantial weight, size, and power-requirement advantages with respect to the current state of the art. The phase 1 project successfully demonstrated 3D-printing of polymer precursors, along with carbonization and activation to produce monoliths with excellent shape, dimensional and ammonia adsorption/desorption properties. The phase 2 objectives are: (1) to optimize sorbent properties and performance; (2) to design, construct, test, and deliver two full-scale TC sorbent prototypes; to provide guidelines for their integration with the plss. This work will be accomplished in six tasks: (1) sorbent development and optimization; (2) subscale sorbent testing at UTC aerospace systems; (3) prototype design; (4) prototype construction; (5) prototype testing; and (6) system evaluation.