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Acoustic Shaping, Inc: Manufacturers in Mars Orbit

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Acoustic Shaping, Inc: Manufacturers in Mars Orbit PROPOSAL AND BUSINESS PLAN SUBMITTED TO THE 1999 "NASA MEANS BUSINESS" STUDENT COMPETITION ACOUSTIC SHAPING, INC: MANUFACTURERS IN MARS ORBIT By the Georgia Tech team Sam Wanis, Don Changeau, Justin Hausaman, Ashraf Charania, Catherine Matos, Richard Ames DECEMBER 1998 I. Proposal Summary The Georgia Tech team proposes a Business Plan for a technical concept which they have demonstrated in '97 and '98 NASA Microgravity flight-tests: Acoustic Shaping as a means of non- contact manufacturing in Space. Acoustic Shaping will offer flexible manufacturing of pressure vessels and precision-formed components using raw material obtained from moons and asteroids. The customers are the space-faring construction industry, as well as bio-engineering companies of the 21st century. Material from lunar and asteroid-based mines will be shipped to manufacturing facilities in Earth and Mars orbit. Finished products will be delivered using aerodynamic decelerators to customers on planetary surfaces, or used in the construction of space station modules and vehicles for other missions. By reducing the cost of manufactured components to a fraction of the cost of Earth-built or machined components, ASI will provide an enabling resource for human exploration of the Solar system. A systematic Implementation Plan is laid out to develop ASI as the aerospace construction industry of the 21st century. From its already-demonstrated technical foundations, the Plan reaches out using the student team's projections of the evolving space industry. This Plan is used to convey a sampling of Georgia Tech's capabilities and interests in NASA's HEDS mission, across disciplines and levels. The team has won support from faculty research teams across the School of Aerospace Engineering, the Dupree College of Business and the GT-Emory School of Biomedical Engineering, each of which brings research and curricular capabilities to this mission. The letter from the Chair of AE, and the participation of a powerful core of expertise, highlight Georgia Tech's support behind the enthusiasm of the student team. This proposal integrates the efforts of both Georgia Tech teams which submitted Letters of Intent to NASA. 1 LIST OF CONTENTS I. Proposal Summary 1 II. Business Plan 3 1. Executive Summary 3 2. Technical Proposal 7 2.1 Introduction 7 2.2 Technology Model & Assumptions 8 2.3 Acoustic Shaping Technology 8 2.4 Implementation Plan 9 2.5 Discussion 9 2.6 Implementation Plan 13 3. Market and Economic Analysis 20 III. Supplemental Information: 23 Georgia Tech capabilities & interests associated with this project 1. School of Aerospace Engineering 23 2. GT/Emory School of BioMedical Engineering 26 3. Dupree College of Business and Management 26 IV. References 28 Selection Criteria Index Issue Pages Planning Issues and Assumptions 9-13 Timeline 5 International partners/customers 4, 7 Academic Department description 23 Course Curriculum Description 23 Outreach Plan 18 Supporting Faculty, Partnerships 24-26 Supporting Faculty Citations 28-31 Team member listing 7, 26 Team Leader Information 26 Letters of Endorsement 32 2 II. BUSINESS PLAN II.1 Executive Summary Acoustic Shaping Inc. EarthBase R&D Center, 225 North Avenue Operational Locations: School of Aerospace Engineering, Solar System Manufacturing Facility: CanalView Business Georgia Institute of Technology Park, Mars Orbit Atlanta GA30332-0150 Earth Regional Manufacturing: ISS Freedom, Low Earth 404-894-9622 Orbit Payload Exchange Operations: Lunar Orbit Station Vision ASI will lead the space-based manufacturing industry of the 21st century. Objectives ASI will provide: · Custom-fabricated parts for the International Space Station. · High-precision, high-purity parts for Earth-based bioengineering industry. · Standardized components for the construction industry in Space. Business Description At $5,000 per lb. to Low Earth Orbit, the cost of shipping components and machine tools from Earth is a large obstacle to the human venture into space. ASI provides a solution to this problem: manufacturing using adaptively-controlled sound waves to form surface shapes in microgravity, from granular or liquid-state materials. ASI will offer non-contact, flexible manufacturing of sophisticated components to Mars explorers and to the construction business in the Solar System. Initial operations located on the International Space Station (ISS) in low Earth Orbit will serve near-term customers on ISS, using material shipped from Earth. As revenue and markets develop, the primary manufacturing facility will be located in lunar orbit to help build the second ISS, and start lunar mining. As this market develops the main manufacturing facility will be built and located at the Mars orbital station. Material brought from lunar and asteroid mines will be turned into precision-formed components at ASI. Products will be delivered by aerodynamic decelerators to customer sites on the planetary surface, and carried on Cycler Shuttles to customer sites in GEO / LEO / lunar orbit. From these beginnings, ASI will lead the space-faring construction business in the Solar System. Market Space-related business accounts for over $121B/yr in 1998. Currently, all items are shipped from Earth, at costs-to-orbit of over $5K per lb. The International Space Station alone is expected to grow to an Earth-weight of over 1 million lbs. by 2004. Demand for Space-based construction is projected to be $20B/yr in 2005, rising to $500B/yr by 2020 as human space exploration progresses. ASI's role in this market is both as market enabler and as supplier. ASI's customer base consists of two types of industries: Orbiting Space Station.[MarsSociety,1998 3 1) NASA and Aerospace firms contracting to NASA and ESA for construction of : § International Space Station components § Spacecraft for Solar System & Deep Space exploration § Lunar and Mars surface base facilities As Space Commercialization proceeds, these firms will transition to serve the developing commercial markets on Earth for the development and habitation of space, with attendant increases in size. Examples of ASI-built products are: · Space-Station outer and interior panels. · Nozzles · Plumbing components · Pre-fabricated, pressurized habitation modules. · Pressure vessels. Artist’s concept of a potential Mars mission, from NASA Web pages, showing connected pressure vessels to form habitation modules. From [Mars Society, 1998 ] Competitive Edge ASI's core technology is the Acoustic Shaping technology proven by our team in over 120 parabolas of microgravity flight on NASA's KC- 135. Our core competence includes the depth and breadth of technical/ business/marketing capabilities from 3 schools and 4 research labs at Georgia Tech, one of the premier technological institutes of the world. Access to Georgia Tech translates into a complete capability across the life-cycle of this technology. These Earth-based facilities offer complete concept-to-test capability, spanning such areas as System Design and Life-Cycle Analysis/Simulation/Optimization, Booster technology, Hypersonic Controls, Spacecraft Attitude Control, Re-entry Aerothermodynamics, Acoustics, Mathematical Modeling & Simulation, and aerodynamic glide/decelerator technologies. ASI's links to the School of Bioengineering at Georgia Tech bring access to an area of rising importance to the human exploration of space. Bioengineering is expected to form a rising share of the mass-market demand on Earth for precision components enabled by ASI's technology. ASI seeks partnerships with the entities leading Space Exploration: NASA, the large aerospace companies Lockheed-Martin and Boeing, as well as a leading technological university, Georgia Tech. The ASI team in particular, and these Georgia Tech schools in general, are models of the future engineering environment envisioned by NASA, our project teams integrating diverse technical disciplines as well as people from all parts of the world. Glimpse of an ASI Manufacturing Facility At the core of the space-based Phase-Controlled Acoustic Shaping Technology (PCAST) facility are 10 Acoustic Chamber modules of various sizes, with up to 25 individually-programmable speaker systems each. The chambers are pressurized with a suitable gas such as nitrogen. Raw material is received at the orbiting station and converted to the desired particle size or liquid characteristics in a preprocessing plant. The temperature and pressure are brought to the needed levels, and a pre- selected sound field is imposed. The material is fed into the chamber along with the binder component, so that the mixture solidifies along the desired surfaces; some processes will use solar / microwave heating or rapid cooling. After curing for the appropriate time, the formed shape removed, finishing processes applied, and the part is loaded back into transporters. 4 Business Location Manufacturing will be located in orbit to use jitter-free, long-duration microgravity essential for quality control. The first location will be at the ISS to serve customers in LEO and GEO. The next will be in lunar proximity, to participate in ISS-2 construction and help initiate lunar mining. With material coming from lunar mines, the Mars station will be built and moved to Mars Orbit, for access to the Martian surface market and to major transfer orbits for missions throughout the Solar System. Mars orbit offers convenient access to Earth, to Earth's Moon, and to the Asteroid Belt. Subsidiary locations in lunar orbit allow exchange between raw materials from the Moon, and finished
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