Alternative Manufacturing for Spacesuit Helmet and Protective Visor SOW (003).docx

Alternative Manufacturing for Spacesuit Pressure Bubble Statement of Work

Contract Mechanism:

RFQ Title:

Contract Type: Firm Fixed Price Expected Cost:

RFQ Requirements:

Evaluation Criteria:

a) Technical Capability

b) Past Performance

c) Price

1. Background:

The Crew and Thermal Systems Division’s Space Suit and Crew Survival Systems Branch is requesting the development of an injection mold, build of a mold, and delivery of a prototype for an injection molded pressure bubble for future spacesuit designs. The development will be based on the design of the Exploration Extravehicular Mobility Unit (xEMU) spacesuit which is the government reference design. The intent of this procurement is to execute initial research and development of manufacturing the xEMU pressure bubble using an injection molded system.

2. Objectives:

The objective of this contract is to execute development and manufacturing of the xEMU pressure bubble using an injection molded system.

Requirements:

2.1 Innermost Dimensions Pressure Bubble

2.1.1 The xPGS Pressure Bubble shall use a hemi-ellipsoid helmet with the bonded helmet ring innermost dimensions of 10" x 13".

2.2 Minimum thickness Pressure Bubble

2.2.1 The xPGS Pressure Bubble shall have a minimum wall thickness of 0.075 inches.

2.3 Outer Dimensions Pressure Bubble

2.3.1 The xPGS Pressure Bubble shall follow the outer dimensions as listed in Figure 1 (listed in inches).

2.4 Dovetail groove Pressure BubbleFigure 1: Outer dimension of xPGS Pressure Bubble as listed in inches.

2.4.1 The xPGS Pressure Bubble should include a dovetail groove following the dimension (as listed in inches) as listed in Figure 2.

Figure 2: Dovetail Groove dimensions for the xPGS Pressure Bubble as listed in inches.

2.5 Critical Area of Vision

2.5.1 The Helmet assembly minimum critical area shall be the entire area except 60 degrees measuring from the zenith edge of the neck ring towards the nadir edge of the neck ring as shown in Figure 3.

Figure 5: Critical area of vision

2.6 Optical quality

2.6.1 The Pressure Bubble imperfections (defined as any pit, scratch, bubble coating imperfection, foreign particles or inclusions) in the critical area of vision should be limited by the Imperfection Parameters Table 1Table 1: Imperfection Parameters

2.7 Haze

2.7.1 Haze in the critical and noncritical areas of the Pressure Bubble prior to coating should not exceed 2 percent as determined in accordance with ASTM D1003. Verification is not required by the vendor.

2.8 Visible light transmission

2.8.1 The Pressure Bubble transmittance percentage in the visible light spectrum (380-800 nm) in both photopic and scotopic conditions shall be a minimum of 82%. Verification is not required by the vendor.

2.9 Refractive Power

2.9.1 Refractive error of the Pressure Bubble in the critical area of vision should not exceed ± 0.125 D (TBD) in the critical area for spherical or cylindrical power in any meridian. Verification is not required by the vendor.

2.10 IVA Contact Load

2.10.1 The Pressure Bubble should be acceptable for nominal EVA operations after an impact during IVA operations of 125 lbs over an area 4"x4". The load can be applied anywhere on the external surface of the suit assembly. Verification is not required by the vendor.

2.11 Ultimate Pressure Load

2.11.1 The Pressure Bubble should have a design ultimate pressure of 21.2 psid. Verification is not required by the vendor.

2.12 Micro-Gravity Impact

2.12.1 The Pressure Bubble should not fail catastrophically following impact with a 2 inch diameter steel ball when manned, pressurized to exploration pressure, in microgravity, translating at 1.4 ft/s, and in the heaviest EVA configuration, approximately 300 lbs. Verification is not required by the vendor.

3. Scope of Work:

3.1 Assessment of Injection Molding for pressure bubble designs

3.1.1 Feasibility

· Evaluate the ability to manufacture the size/shape required of the pressure bubble to the requirements detailed in section 2.0 as executed by a market survey, simulations, etc.

· If needed, recommend design changes to the pressure bubble to improve manufacturability.

3.1.2 Mold Design and Surface Properties

· Evaluate effective mold design and required surface properties to meet the requirements detailed in section 2.0.

· If needed, recommend design changes to the pressure bubble to improve manufacturability.

3.2 Manufacturing

3.2.1 Prototype

· Build 1 flat panel sample for NASA to verify optical properties and coating adhesion (coatings applied by NASA)

3.2.2 Molds: Build mold

· Pressure Bubble

3.2.3 Visors

· Build Pressure Bubbles (Deliver 5 highest quality prototypes to NASA)

4. Deliverables:

4.1 Monthly status meetings

Status meetings will occur each month to update the government on the project. The deliverable of the monthly status meeting will be a PowerPoint presentation.

4.2 Mold design Presentation:

The vendor will provide a mold design presentation that will communicate the feasibility, mold design for injection mold production, design of the proposed finished products, and any additional information for how the Pressure Bubble meets requirements identified in Section 2. The deliverable of the delivery presentation will be a PowerPoint presentation.

4.3 Hardware:

The vendor will deliver the flat panel prototype and 5 pressure bubbles to Johnson Space Center on the shipping requirements as defined in section 5. Hardware shall be delivered with an Acceptance Data Package that includes at minimum:

· Material certifications

· Inspection records

5. Shipping Requirements

5.1 Ship all hardware to the following address, unless otherwise directed:

NASA LYNDON B. JOHNSON SPACE CENTER

BLDG.420,CENTRAL RECEIVING

2101 NASA PARKWAY

HOUSTON, TEXAS 77058

Deliver to: Bldg.7A/RM-320 (Controlled Storage) Attn: Kristine Davis, Project Code-02226

Hardware shall be delivered as Class III to NASA with all hardware listed on a DD Form 250, with the following information listed, at minimum:

· Contract and Task Order Number

· Part Number

· Lot #

· Serial # (if applicable)

· Nomenclature

· Shelf Life

· Quantity

· Class: III

· Unit cost

· Total Cost

6. Period of Performance / Schedule:

All products identified in section 4 shall be delivered by 6 months from ATP.

7. Travel:

None.

8. Duty Information:

None.

9. Quality Requirements -- Certificate of Compliance (C of C) Supplier shall provide a certification with each shipment to attest that the parts, assemblies, subassemblies, or detail parts conform to the Order requirements. When applicable, the true manufacturers, lot, heat, batch, date code, and/or serial number must appear on the certification.

Certification shall contain the following:

· Customer’s Order number

· Product name

· Part and Serial number

· Name and address of manufacturing or processing location

· Manufacturer’s lot, heat, batch, date code, and/or serial number (if applicable)

· Quantity and unit of measurement (each, box, case, gallons, etc.)

· Be signed and dated by an official of the company

10. Other Considerations:

None.

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