SOW.pdf
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- Attached to
- Plan and Fabricate Truss Elements for Thermoplastic Development of Exploration Applications. Federal contract opportunity
- Solicitation number
- 80NSSC24872044
About this file
This document is a Statement of Work (SOW) for the Thermoplastic Development for Exploration Applications (TDEA) Thermoplastic Space Point Design (TSPD) Repeating Unit Cell Truss Element.
The SOW defines the materials, information, and hardware that NASA will provide to the vendor, as well as the deliverables the vendor shall supply to enable the TSPD RUC demonstration. The vendor shall layup, consolidate, and perform non-destructive evaluation (NDE) on 28 TSPD truss elements using government-furnished equipment (GFE) tooling. The vendor shall deliver the truss elements, including the joint splice plates, diagonal, horizontal, and vertical truss members to Agile Ultrasonics for welding. The SOW specifies the required partial and final deliveries, shipping instructions, and period of performance from May 2024 to August 2024. There are no travel or other direct cost requirements.
The related federal contract opportunity is a pre-solicitation notice for a sole-source contract to Wichita State University's National Institute of Aviation Research (NIAR) to plan and fabricate the truss elements for the TDEA project. NASA intends to issue the contract under the authority of FAR 13.106-1(b)(1)(i), as NIAR has the unique facilities and prior manufacturing development work for this effort. Interested organizations may submit their capabilities and qualifications by June 15, 2023.
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TDEA TSPD Repeating Unit Cell Truss Element SOW (May 22, 2024)
Summary/Background
Thermoplastics Development for Exploration Applications (TDEA) seeks to advance thermoplastic composite material structures technology. This includes demonstration of a relevant structural concept called the Thermoplastic Space Point Design (TSPD). The TSPD effort shall establish in-space manufacturing and weld technologies that can be applied to truss structures. The TSPD is 150 feet tall conceptual truss structure. The full truss is based on a section repeated 17 times and is called the TSPD Repeating Unit Cell (RUC).
TDEA needs a series of truss members and joint splice plates to demonstrate ultrasonic weld methods based on the RUC. The TSPD RUC and a joint with all truss elements combined are shown in figure 1.
The vendor shall build the truss members and deliver them to Agile Ultrasonics for welding. All parts are made from Toray TC1225/T700 slit tape material using Automated Fiber Placement. NASA provides the tape material for this effort. The vendor manufactures all parts and inspect all parts prior to delivery. There are (4) truss element configurations to build. Prior work effort provides some of the needed joint splice plates. The layup tooling is provided by NASA. The tooling design incorporates NIAR part spring-back results. The vendor shall identify development efforts needed based on prior experience or produce a first part demonstration. This SOW defines the materials, information and hardware NASA will supply to the vendor, and the deliverables the vendor shall supply that enables TDEA TSPD RUC demonstration.
Figure 1: TSPD RUC assembly and joint inside and outside closeups
Tasks / Requirements Government Provided Equipment (GFE) and Materials: NASA will provide the following to the vendor to accomplish described work.
Released TSPD drawings.
Material TC1225/T700 145GSM 34% RC previously slit for this effort.
A set of 4 layup tools and 4 consolidation tools.
NDE standards
Relevant Drawings: NASA will provide the following drawings.
Truss Element o TDEA-400: TSPD Joint Splice Plate o TDEA-401 TSPD Diagonal Truss Member o TDEA-402 TSPD Horizontal Truss Member o TDEA-403, TSPD Vertical Truss Member o TDEA-633, TSPD Joint Splice Plate Consolidation Tool o TDEA-636, TSPD Truss Member Layup Tool, Box Configuration
Reference NDE standards o The following panels were made under a prior effort. They are the same laminates with intentional defects ¼ and ½ way through the laminate to be used as NDE calibration.
TDEA-431, TSPD Diagonal Truss, Flat Panel TDEA-433, TSPD Horizontal Truss, Flat Panel TDEA-435, TSPD Vertical Truss, Flat Panel TDEA-437, TSPD Joint Splice Plate, Flat Panel
Development Planning:
The vendor shall identify development activities needed to ensure the parts can be made to drawing tolerances, and NDE can find the 0.25 inch diameter defects. If no development is needed, the vendor shall build, inspect and report results from a first article prior to building the full set of parts. A schedule shall be presented to show manufacturing development, or first article, integrated with truss element deliverable dates provided.
Fabrication Effort.
The vendor shall layup, consolidate, and NDE 28 TSPD truss elements using GFE tooling.
Parts that pass NDE evaluation shall be cut to the drawing configuration and inspected to the drawing requirements. Non-conformances found shall be reported for each part. NDE shall be reported with or without anomalies.
NDE Requirement
NDE shall be performed by the vendor using a technique demonstrated to find flaws 0.25 inch in diameter or larger. Demonstration is based on NDE standards referenced earlier. All detectable flaws shall be reported. Flaws smaller than 0.25 inch that agglomerate to 0.25” or larger shall be reported. Defects regions shall be identified on the part with a high contrast marker, and captured in NDE reports with the reference part number.
Deliverables Process Planning:
Provide a development plan including work flow and schedule. This can be a MS Word or MS PowerPoint presentation – 2 weeks after receiving order (ARO) o Hold a process planning meeting – 3 weeks ARO
Reporting
The vendor shall provide weekly written status reports via email, or in a telecon. Status shall include work accomplishments for that time period and plans for the next period. The vendor shall report all anomalies that result in a schedule impact of greater than one week within 48 hours of occurrence. The problem report shall include definition of the problem encountered, the root cause, corrective action, and schedule impact.
Structure Element Process Development
For identified process development steps, deliver trial data, and recommended process for truss element fabrication.
If no process development occurs, provide first article inspection results including NDE, and dimensional inspection results.
TSPD Vertical Sub-Element Part Fabrication and NDE
Partial deliveries are encouraged. The order of preference is shown in the list below, the first being the highest priority. Part deliverables include NDE and dimensional inspections serialized to each part.
TSPD 400: Joint Splice Plate o Deliver 4 for Weld Development – Jun 29, 2024
TSPD-403: Vertical Truss Element o Deliver 8 TDEA-403-02 (short parts) for weld development – Jun 29, 2024 o Deliver 8 TDEA-403-01 (full length) for RUC Assembly – Aug 23, 2024
TSPD-401: Diagonal Truss Element o Deliver 8 for RUC Assembly – Aug 23, 2024 TSPD-402: Horizontal Truss Element o Deliver 12 for RUC Assembly – Aug 23, 2024
Element Shipping Truss Elements shall be shipped to Agile Ultrasonics at the following address:
Agile Ultrasonics Corp 4621 Lyman Dr.
Columbus, OH 43206
Attn: Jim Stratton 614.264.1272
Part Drop Shipping Part drop / edge trim shall be marked with the part number of the component it came from, bagged, and shipped to GSFC.
Ken Segal GSFC Code 543 Bld 5 Room C200C Greenbelt, MD 20771
Period of Performance May 2024 to Aug 2024.
Travel / ODC Requirements None.
Technical POC
Name : Ken Segal/GSFC Title: Aerospace Engineer Phone Number: 301-286-2895
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