NEAS_SOW_Flight_Unit.docx

09/27/16 SOW

Statement of Work

Near Earth Asteroid Scout Solar Sail and Triangular Rollable and Collapsible (TRAC) Boom Flight Unit Procurement

1.0 Summary of Activities

The contractor shall support the Marshall Space Flight Center (MSFC) solar sail team by designing, fabricating, processing, testing, and delivering a solar sail restraint, a 86m2 solar sail, and four 6.8m triangular rollable and collapsible (TRAC) booms for flight on the 6U Near Earth Asteroid (NEA) Scout mission. Additional tasks include repair of the post-deployment flight solar sail, refolding the flight solar sail, and spooling the flight solar sail. The Contractor shall demonstrate application of lessons learned during the initial fabrication, repair, fold, and spooling of the Engineering Development Unit (EDU) solar sail. The contractor shall provide subject matter experts, experienced technicians, and a local manufacturing facility that can support the NEA Scout solar sail flight unit and TRAC booms. As needed, process improvements can be made to produce a better quality product. These improvements shall be discussed with MSFC/National Aeronautics and Space Administration (NASA) before implementation. All flight hardware shall be handled by subject matter experts with non-powdered gloves latex or nitrile gloves. The flight hardware shall adhere to NASA Quality Assurance best practices and assessed to acceptance criteria prior to hardware delivery to NASA MSFC Marshall Space Flight Center.

The period of performance is from authorization to proceed through 12 months.

The contractor shall provide a schedule within the first three weeks of contract award. The schedule shall be approved by NASA MSFC Marshall Space Flight Center prior to start of tasks. Schedule variations and slips shall be communicated within 24 hours of a cause. The updated schedule shall be reapproved due to schedule variances by NASA MSFC Marshall Space Flight Center.

The NASA MSFC shall perform a pre-shipment inspection of the hardware before packaging for transportation to NASA MSFC. NASA MSFC shall perform a post-shipment inspection of the hardware after receipt from contractorNeXolve at NASA MSFC.

The Contractor shall conduct the following primary tasks in support of the activity:

1. Design and fabricate a sail restraint of 2mil Kapton material with Kapton break-away tabs to incase the solar sail while stowed on the sail spool. The sail restraint shall have the following characteristics:

a. Dimensions 38.1 x 24.8 (cm).

b. 2 mil Kapton.

c. Features are heat formed to cover sail spool topography.

d. Sail restraint is secured onto sail spool assembly without any exposed adhesive to the sail material.

e. No sharp edges on corner reinforcement pieces.

f. Fully stowed sail shall be contained within the outline of the sail spool.

g. Fabricate and deliver a removable sail protector for transportation and storage.

h. Test to demonstrate to customer successful restraint and release.

i. Perform acceptance checks of hardware per NEAS-SPEC-001 prior to delivery to NASA MSFC. Marshall Space Flight Center

2. Design, manufacture and process the solar sail flight unit:

a. Update design, with NASA engineer assistance, to include modifications as a result of EDU lessons learned, including the addition of a ground strap at the center of the sail.

b. Fabrication of the 86m2 clear polyimide (CP1) solar sail per NEAS-SPEC-001.

c. Fold the 86m2 CP1 solar sail.

i) Each fold will be 2.5-2.75in in height along the length of the sail.

d. Integrate the sail restraint onto the NASA provided solar sail spool assembly.

e. Spool the 86m2 CP1 solar sail onto the NASA provided solar sail spool assembly with a mechanical assist apparatus.

f. Perform acceptance checks of hardware per NEAS-SPEC-001 prior to delivery to NASA MSFC. Marshall Space Flight Center

3. Manufacture four 6.8m TRAC booms meeting NASA acceptance criteria per NEAS-SPEC-002:

a. Fabrication of the 6.8m TRAC booms per NEAS-SPEC-002.

b. Incorporation of root and tip conditions.

c. Perform acceptance checks of hardware per NEAS-SPEC-002 prior to delivery to NASA MSFC.Marshall Space Flight Center

4. Support NEA Scout solar sail subsystem test activities at NASA MSFC Marshall Space Flight Center in Huntsville, AL.

a. Participation in weekly meetings and review boards.

b. Technicians and subject matter experts present during solar sail subsystem test activities.

c. On site solar sail repair due to damage caused by handling, transportation, deployment, and other factors.

5. Delivery of support documentation:

a. Acceptance data package.

b. Certificate of compliance.

c. Progress reports.

d. Pre-shipment review presentation of hardware.

In support of MSFC the Contractor shall:

2.0 Task 1 – Design and Fabrication of Sail Restraint

Task Description – Construct and deliver a sail restraint flight unit. The contractor shall build Quantity (1) 38.1 cm X 24.8 cm sail restraint. The sail restraint shall be made of a uniform material, 2mil Kapton, with a minimum of Qty (24) break away tabs made of Kapton. All design features and design hardware shall require approval by NASA/MSFC Engineering prior to fabrication. The contractor shall provide a Qty (8) spare break away tabs to NASA/MSFC at delivery of the flight unit. The contractor shall provide additional break away tabs if needed.

The contractor shall integrate the sail restraint onto the NASA provided solar sail spool assembly flight unit. The sail restraint shall be secured onto sail spool assembly flight unit without any exposed adhesive to the sail material. Sharp edges on corner reinforcement pieces shall not be present.

The sail restraint shall consist of heat formed design features to accentuate fold lines and cover sail spool topography that could damage the solar sail. The design shall be consistent, with design improvements, with the sail restraint provided during the engineering development unit activities. The contractor shall test to demonstrate to customer successful restraint and release with the customer present. Restraint drawing can be found in NEAS-SPEC-001.

3.0 Task 2 – Solar Sail Flight Unit

Task Description – Manufacture and deliver a Quantity (1) 86m2 solar sail flight unit. The contractor shall build the solar sail flight unit per NEAS-SPEC-001. The solar sail shall include features such as border reinforcement, carbon fiber reinforced corners for the sail-boom interface, compliant borders, catenaries, seams and ripstops, and a reinforced center hole. The solar sail flight unit shall be made of Colorless Polymer-1 with a vapor deposited aluminum coating for reflectivity properties. The vapor deposited aluminum coating shall have optical reflectivity between 88% and 93%. The solar sail flight unit shall have a minimum uniform thickness of 2.5 microns throughout the acreage of the solar sail area with the exception of the seams, ripstops, and reinforced features. The seams, ripstops, and reinforced features shall be thicker than the 2.5 micron solar sail area.

The solar sail CP1 gores shall be inspected for imperfections and damage such as but not limited to scratches, holes, tears, and non-uniform vapor deposited aluminum coating. Any gores that do not meet acceptance criteria per NEAS-SPEC-001 shall not be used for the flight sail.

Any repairs needed during sail manufacturing shall be approved by NASA Quality Assurance prior to proceeding with repair activity.

The design shall be consistent, with design improvements, with the solar sail unit provided during the engineering development unit activities. All design features and design hardware shall require approval by NASA/MSFC Engineering prior to fabrication.

Prior to sail folding activities, the contractor shall display a fully deployed solar sail as-built flight unit for verification test activities. The contractor and customer shall perform acceptance checks of hardware per NASA-SPEC-001 prior to delivery to NASA Marshall Space Flight Center.

The contractor shall perform adhesiveless solvent bond along the length of the Gores during sail fabrication. The contractor shall use adhesiveless 1mil or 2mil Kapton as reinforcement along the sail border, center hold, and catenaries.

The contractor shall not use talc powder or equivalent powder-like substance during manufacturing and repair of the solar sail flight unit.

After the contractor and NASA perform verification tests and accept the solar sail flight unit, the contractor shall fold the solar sail to integrate onto the NASA provided solar sail spool assembly flight unit. The folds shall be 2.5 inch to 2.75 inch in width along the 366 inch edge of the solar sail. The maximum allowable width of each fold is 3.0 inches. The sail fold process shall be consistent with the sail fold process utilized during the engineering development unit process. Lessons learned shall be applied to the fold process per approval from NASA Marshall Space Flight Center.

The solar sail folds may be held with magnets, paper clips, and plastic tabs that are marked with bright colors. There shall be no sharp corners on the fold guides or plastic tabs during folding activities. Personnel shall wear gloves during folding activities. Minimum handling of the sail is encouraged. To reduce static attraction to the surface areas of the tables, teflon sheets should be laid on the table prior to sail folding to prevent static cling to the table surface. All measures shall be taken to prevent damage to the sail during folding activities. Only qualified personnel shall have contact with the solar sail during folding activities.

Once the sail is folded, the contractor shall integrate the solar sail flight unit onto the NASA provided solar sail spool assembly flight unit. The solar sail flight unit shall be integrated onto the solar sail spool assembly flight unit with a mechanical assist apparatus. The mechanical assist apparatus shall be operated consistently with the process used with the engineering development unit. Lessons learned shall be applied to the spooling process per approval from NASA Marshall Space Flight Center prior to use on the solar sail flight unit.

4.0 Task 3 – TRAC Booms

Task Description – Manufacture and deliver a Quantity (4) 6.8 meter Triangular Rollable and Collapsible (TRAC) booms made of Elgiloy, a stainless steel alloy. The contractor shall build the TRAC boom flight units per NASA-SPEC-002. The TRAC booms shall include root and tip condition features as called out in NASA-SPEC-002. The TRAC booms shall have a final delivery length of 6.8 meters. The TRAC booms shall have no twist, weld breaks, cracks, or curvature beyond 5 centimeters out of plane. Minimum surface discoloration, ripples, and dents due to manufacturing processes are allowed. The first boom produce shall be accepted as a first article sample.

The design shall be consistent, with design improvements, with the TRAC booms provided during the engineering development unit activities. All design features and design hardware shall require approval by NASA/MSFC Engineering prior to fabrication. The contractor shall demonstrate process control of the manufacturing method and have approval from NASA MSFC engineering before proceeding. The contractor shall provide a defect list and description and evaluate effects on boom performance.

The contractor shall provide facilities and personnel to support verification tests and inspections prior to NASA Marshall Space Flight Center acceptance.

5.0 Task 4 – Support Test Activities

Task Description – The contractor shall provide subject matter experts and technicians to support solar sail flight unit test activities to be performed at NASA Marshall Space Flight Center and at the contractor site. The test activities shall include but are not limited to boom only deployments, random vibration, thermal vacuum, and solar sail deployments. The tests will be performed at the subsystem level and at the integrated flight system level. The contractor shall provide a solar sail repair kit and perform on-site solar sail repair due to damage caused by handling, transportation, deployment, and other factors.

The contractor shall participate in weekly team meetings. The contractor shall provide a weekly summary of progress report, with at minimum a bulleted list of actions completed, actions scheduled, future forecast, and variances in accordance with DRD 1602MA-001. The weekly summary format may be a quad chart or word document submitted to the project. The contractor shall support engineering review boards hosted by the NEA Scout project team on an as needed basis.

6.0 Task 5 – Delivery of Support Documentation

Task Description – The contractor shall provide documentation for traceability of hardware through the design, manufacturing, and repair of the solar sail restraint, solar sail, and TRAC booms. The contractor shall provide an acceptance data package (see Appendix A) and certificate of compliance upon delivery of the flight hardware to NASA MSFC. The contractor shall provide a written progress report (i.e. power point or word document) throughout the period of performance, to be presented during weekly team meetings. The contractor shall provide support and presentation materials for the Pre-Shipment review prior to delivery of the integrated flight system to the dispenser contractor.

Description of Service: Engineering Support Activities

1. Final design of flight solar sail and TRAC booms

2. Final design of sail restraint

3. Technical support for fabrication and manufacturing of flight hardware

4. Performance of sail fold, repairs, and spooling

5. Facility access

Description of Deliverables: Flight Hardware and Reports

1. Solar Sail Flight Restraint (Qty 1)

2. Solar Sail Flight Unit – folded and spooled (Qty 1)

3. Repaired 86m2 CP1 solar sail flight unit – folded and spooled (Qty 1)

4. Four 6.8m TRAC Boom for flight (Qty 4)

5. Acceptance Data Package

6. Certificate of Compliance

7. Progress Reports

8. Pre-Shipment Review Presentation

Partial Payment Schedule

1. Milestone 1: Solar Sail and TRAC Boom Design Complete – 4 weeks after ATP

2. Milestone 2: TRAC Boom Delivery – 5 months after ATP

3. Milestone 3: Solar Sail Delivery – 6 months after ATP

4. Milestone 4: Completion of flight unit testing and engineering support – 12 months after ATP

5. Milestone 1: Solar Sail and TRAC Boom Design Complete – 4 weeks after ATP

6. Milestone 2: TRAC Boom Manufacturing Complete – 4 months after ATP

7. Milestone 3: TRAC Boom Delivery – 5 months after ATP

8. Milestone 4: Solar Sail Delivery – 6 months after ATP

The Contractor shall report and document this work and fulfill the requirements of associated Data Requirements Description (DRD) as outlined in Data Procurement Document (DPD) 1602 (Attachment J-2). The contractor shall determine the data restriction that applies to each data deliverable and mark or transmit the data restriction in accordance with section 2.3.3 of the Data Procurement Document.

The contractor shall prepare and submit the Environmental Compliance Reports that complies with Executive Order 13693 in accordance with DRD 1602EE-001.

The Contractor shall establish and implement an industrial safety, occupational health, and environmental program that provides a workplace free from recognized hazardous conditions and is incident and injury free by (1) preventing employee fatalities, (2) reducing the number of incidents and severity of employee injuries and illnesses, and (3) protecting the environment through the ongoing planning, implementation integration and management control of these programs. The Contractor shall comply with all Federal, State, NASA, and Center specific SHE-related requirements and regulations applicable to this contract listed in MPR 8715.1, “Marshall Safety, Health and Environmental (SHE) Program” while working on-site at MSFC and provide a signed Alternate Safety, Health, and Environmental (SHE) Plan in accordance with DRD 1602SA-001.

The contractor shall report mishaps and safety statistics to the MSFC Industrial Safety Branch in accordance with DRD 1602SA-002. The contractor shall submit directly into the NASA Mishap Information System (NMIS) or shall use the forms listed in section 15.4 of DRD 1602SA-002 or electronic equivalent to report mishaps and related information required to produce the safety metrics.

Appendix A: Content of Acceptance Data Package An Acceptance Data Package (ADP) for hardware contract configuration items shall contain the current log book that includes:

1. Test history log, including post manufacturing checkout and final verification tests of the hardware, with the following data:

a. Actual measurements identified to specified tests. Reference to applicable test reports are satisfactory provided that copies of the reports are provided.

b. Brief test summary.

c. List of unaccomplished tasks and estimated man-hours to complete.

d. List of actual and recommended retest.

e. Special test instructions, investigations, warnings, and problems encountered during test.

f. Failure and corrective actions data for all failures during all testing.

2. Inspection records for all inspections.

3. Transfer records providing a history of all hardware and critical component movements.

4. Alignment data for TRAC booms.

5. Component log books, including Government furnished items.

6. Mass logs (in kilograms or grams) of each hardware.

7. Configuration Records:

a. Parts and drawing list identifying all parts and incorporated or pending changes to each.

b. List of approved and pending deviations and waivers.

c. Complete list of hardware items shipped loose or separately.

d. Copy of proposed DD Form 250.

e. As-Built Parts List

f. As-Designed Parts List

NASA MSFC Technical POCs:

Tiffany Russell Lockett, ES11 Solar Sail Systems Engineer Project Systems Engineering Branch Space Systems Department NASA Marshall Space Flight Center Tiffany.lockett@nasa.gov Office: (256) 961-1304

FP30: Leslie McNutt, NEA Scout Program Manager Exploration & Space (FP30) Transportation Development Office Leslie.mcnutt@nasa.gov Office: (256) 544-1611 Cell: 256-412-7574

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