SATPC0039031 Tab 04 4 SOW Updated.pdf

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) Experience

• Minimum experience of injection molding previous prototypes of optically clear polycarbonate domes greater than 10 inches

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 design of the pressure bubble for future spacesuit helmet 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 mold design for the xEMU pressure bubble and protective visor using an injection molded system.

2. Objectives:

The objective of this contract is to execute development and design of the mold to manufacture an xEMU pressure bubble using an injection molded system with polycarbonate material.

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 Bubble

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

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

Figure 1: Outer dimension of xPGS Pressure Bubble as listed in inches.

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 1. Verification is not required by the vendor.

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.

Figure 3: Critical area of vision

Table 1: Imperfection Parameters

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 and Mold Design

• Develop injection mold design of the xEMU pressure bubble using polycarbonate material resin including gating strategies, mold flow analysis, external holding fixtures, etc., to meet the requirements and required surface properties as detailed in section 2.

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

3.1.2 Sample plaques

• Provide sample plaques with selected resins and material data/spec sheets to NASA for selecting polycarbonate material

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 Polycarbonate material samples

The vendor will provide sample plaques with selected resin and material data/spec sheet to

NASA.

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 3 months from ATP.

7. Travel:

None.

8. Duty Information:

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: