SATPC0042103 Tab 04 4 SOW _Redacted.pdf

Alternative Manufacturing for Spacesuit Inner Sun Visor

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 Inner Sun Visor 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 Inner Sun Visor using an injection molded system.

2. Objectives:

The objective of this contract is to execute development and manufacturing of the xEMU Inner

Sun Visor using an injection molded system.

Requirements:

2.1 Outer Dimensions Inner Sun Visor

The xPGS Inner Sun Visor shall be a 60 deg wedge that is 12.14 (+00/-.01) inches wide with a radius of 7.586”.

2.2 Optical quality

Figure 1: Critical area of vision

2.2.1 The Inner Sun Visor 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.

2.3 Haze

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

2.4 Visible light transmission

2.4.1 The Inner Sun Visor 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.

2.5 Refractive Power

2.5.1 Refractive error of the Inner Sun Visor 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.

2.6 IVA Contact Load

2.6.1 The Inner Sun Visor 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.

2.7 Micro-Gravity Impact

2.7.1 The Inner Sun Visor 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 Inner Sun Visor designs

Table 1: Imperfection Parameters

3.1.1 Feasibility

• Evaluate the ability to manufacture the size/shape required of the Inner Sun Visor to the requirements detailed in section 2.0 as executed by simulations

• If needed, recommend design changes to the Inner Sun Visor 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.

• Post machining to be maintained to a minimum, expect for necessary deburring or if necessary, please advise NASA team.

• All chamfers, fillets, and rounds to be molded and not post machined

3.2 Manufacturing

3.2.1 Molds: Build mold

• Inner Sun Visor

3.2.2 Visors

• Build Inner Sun Visor (Deliver 10 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 Inner Sun Visor meets requirements identified in Section 2.

Design information to be included: wall thickness, draft, knit/weld lines, sink, warpage, ribs/bosses, tolerance feasibility, gate type/location, and venting strategy. The delivery presentation will be a PowerPoint presentation.

4.3 Process Definition and Control Plan

a) Process Flow Diagram covering raw material receipt through finished goods shipment.

b) Standard Operating Procedures (SOPs)/Work Instructions (WIs) for:

• Nominal process parameters and control limits. Examples: Barrel/zone temperatures, mold temperature, injection speed/pressure, pack/hold profile, cooling time, cushion, screw speed/backpressure, clamp force, cycle time, and alarm limits.

• Resin information to be included is crying time and temperature, moisture content target before molding, shrink rate of material, material technical data sheet.

4.4 Hardware:

The vendor will deliver 10 Inner Sun Visors 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)

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:

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: