aerospace

15 Articles

A Space Walk Through ISS

September 24, 2024 by 14 Comments

The International Space Station (ISS) might not be breaking news, but this February, National Geographic released a documentary that dives into the station’s intricate engineering. It’s a solid reminder of what human ingenuity can achieve when you put a team of engineers, scientists, and astronauts together. While the ISS is no longer a new toy in space, for hackers and tinkerers, it’s still one of the coolest and most ambitious projects ever. And if you’re like us—always looking for fresh inspiration—you’ll want to check this one out.

The ISS is a masterpiece, built piece by piece in space, because why make things easy? With 16 pressurized modules, it’s got everything needed to keep humans alive and working in one of the harshest environments imaginable. Add in the $150 billion price tag (yes, billion), and it’s officially the most expensive thing humans have ever built. What makes it especially interesting to us hackers is its life support systems—recycling water, generating oxygen, and running on solar power. That’s the kind of closed-loop system we love to experiment with down here on Earth. Imagine the implications for long-term sustainability!

But it’s not just a survival bunker in space. It’s also a global science lab. The ISS gives researchers the chance to run experiments that could never happen under Earth’s gravity—everything from technology advancements to health experiments. Plus, it’s our testing ground for future missions to Mars. If you’re fascinated by the idea of hacking complex systems, or just appreciate a good build, the ISS is a dream project.

Catch the documentary and dive into the world of space-grade hacking. The ISS may be orbiting out of sight, but for those of us looking to push the boundaries of what’s possible, it’s still full of inspiration.

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A photo of a farmer in Kazakhstan wearing a balaclava mask standing in front of a farm house with a rusting piece of Soyuz space capsule used as part of the farm's animal feed trough

One Giant Steppe For Space Flight

September 9, 2024 by 16 Comments

In a recent photo essay for the New Yorker magazine, author Keith Gessen and photographer Andrew McConnell share what life is like for the residents around the launch facility and where Soyuz capsules land in Kazakhstan.

Read the article for a brief history of the Baikonur spaceport and observations from the photographer’s fifteen visits to observe Soyuz landings and the extreme separation between the local farmers and the facilities built up around Baikonur. A local ecologist even compares the family farmers toiling around the busy spaceport to a scene our readers may be familiar with on Tatooine.

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Sharkskin Coating Reduces Airliner Fuel Use, Emissions

August 23, 2023 by 66 Comments

The aviation industry is always seeking advancements to improve efficiency and reduce carbon emissions. The former is due to the never-ending quest for profit, while the latter helps airlines maintain their social license to operate. Less cynically, more efficient technologies are better for the environment, too.

One of the latest innovations in this space is a new sharkskin-like film applied to airliners to help cut drag. Inspired by nature itself, it’s a surface treatment technology that mimics the unique characteristics of sharkskin to enhance aircraft efficiency. Even better, it’s already in commercial service! Continue reading “Sharkskin Coating Reduces Airliner Fuel Use, Emissions” →

Robot 3D Prints Giant Metal Parts With Induction Heat

March 29, 2023 by 36 Comments

While our desktop machines are largely limited to various types of plastic, 3D printing in other materials offers unique benefits. For example, printing with concrete makes it possible to quickly build houses, and we’ve even seen things like sugar laid down layer by layer into edible prints. Metals are often challenging to print with due to its high melting temperatures, though, and while this has often been solved with lasers a new method uses induction heating to deposit the metals instead.

A company in Arizona called Rosotics has developed a large-scale printer based on this this method that they’re calling the Mantis. It uses three robotic arms to lay down metal prints of remarkable size, around eight meters wide and six meters tall. It can churn through about 50 kg of metal per hour, and can be run off of a standard 240 V outlet. The company is focusing on aerospace applications, with rendered rocket components that remind us of what Relativity Space is working on.

Nothing inspires confidence like a low-quality render.

The induction heating method for the feedstock not only means they can avoid using power-hungry and complex lasers to sinter powdered metal, a material expensive in its own right, but they can use more common metal wire feedstock instead. In addition to being cheaper and easier to work with, wire is also safer. Rosotics points out that some materials used in traditional laser sintering, such as powdered titanium, are actually explosive.

Of course, the elephant in the room is that Relativity recently launched a 33 meter (110 foot) tall 3D printed rocket over the Kármán line — while Rosotics hasn’t even provided a picture of what a component printed with their technology looks like. Rather than being open about their position in the market, the quotes from CEO Christian LaRosa make it seem like he’s blissfully unaware his fledgling company is already on the back foot.

If you’ve got some rocket propellant tanks you’d like printed, the company says they’ll start taking orders in October. Though you’ll need to come up with a $95,000 deposit before they’ll start the work. If you’re looking for something a little more affordable, it’s possible to convert a MIG welder into a rudimentary metal 3D printer instead.

Magnesium: Where It Comes From And Why We’re Running Out

November 1, 2021 by 94 Comments

Okay, we’re not running out. We actually have tons of the stuff. But there is a global supply chain crisis. Most of the world’s magnesium is processed in China and several months ago, they just… stopped. In an effort to hit energy consumption quotas, the government of the city of Yulin (where most of the country’s magnesium production takes place) ordered 70% of the smelters to shut down entirely, and the remainder to slash their output by 50%. So, while magnesium remains one of the most abundant elements on the planet, we’re readily running out of processed metal that we can use in manufacturing.

Nikon camera body
The magnesium-alloy body of a Nikon d850. Courtesy of Nikon

But, how do we actually use magnesium in manufacturing anyway? Well, some things are just made from it. It can be mixed with other elements to be made into strong, lightweight alloys that are readily machined and cast. These alloys make up all manner of stuff from race car wheels to camera bodies (and the chassis of the laptop I’m typing this article on). These more direct uses aside, there’s another, larger draw for magnesium that isn’t immediately apparent: aluminum production.

But wait, aluminum, like magnesium is an element. So why would we need magnesium to make it? Rest assured, there’s no alchemy involved- just alloying. Much like magnesium, aluminum is rarely used in its raw form — it’s mixed with other elements to give it desirable properties such as high strength, ductility, toughness, etc. And, as you may have already guessed, most of these alloys require magnesium. Now we’re beginning to paint a larger, scarier picture (and we just missed Halloween!) — a disruption to the world’s aluminum supply.

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Image of detonation engine firing

Japanese Rocket Engine Explodes: Continuously And On Purpose

September 2, 2021 by 62 Comments

Liquid-fuelled rocket engine design has largely followed a simple template since the development of the German V-2 rocket in the middle of World War 2. Propellant and oxidizer are mixed in a combustion chamber, creating a mixture of hot gases at high pressure that very much wish to leave out the back of the rocket, generating thrust.

However, the Japan Aerospace Exploration Agency (JAXA) has recently completed a successful test of a different type of rocket, known as a rotating detonation engine. The engine relies on an entirely different method of combustion, with the aim to produce more thrust from less fuel. We’ll dive into how it works, and how the Japanese test bodes for the future of this technology.

Deflagration vs. Detonation

Humans love combusting fuels in order to do useful work. Thus far in our history, whether we look at steam engines, gasoline engines, or even rocket engines, all these technologies have had one thing in common: they all rely on fuel that burns in a deflagration. It’s the easily controlled manner of slow combustion that we’re all familiar with since we started sitting around campfires. Continue reading “Japanese Rocket Engine Explodes: Continuously And On Purpose” →

Let’s Take A Closer Look At This Robotic Airship

July 22, 2020 by 30 Comments

It’s not a balloon, however shiny its exterior may seem. This miniature indoor robotic airship created by the University of Auckland mechanical engineering research group [New Dexterity] is an asymmetric system experimenting with the possibilities of an open-source helium-based airship.

Why a helium airship, as opposed to a fixed wing aircraft? The group wanted to experiment with the advantages of lighter-than-air (LTA) travel, namely the higher mobility and looser path planning constraints. Furthermore, LTA airships have a less obstructed field of vision and fewer locomotion issues. While unmanned aerial vehicles (UAV) may be capable of hovering in one place, their lift is generated by rotor thrust, which drains their batteries quickly in the order of minutes. LTA airships can hover for longer periods of time.

The design was created for educational and research purposes, focusing on the financial feasibility of manufacturing the platform, the environmental impact of the materials, and the helium loss through the balloon-like envelope. By measuring these parameters, the researchers are able to study the effects of circumstances such as the cost of indoor commercial balloons and the mechanical properties of balloon materials.

The airship gondola was designed and 3D printed in a modular fashion, then attached to the envelope with Velcro. The placement with respect to the horizontal symmetry of the gondola was done for flight stability, with several configurations tested for the side rotor angle.

The group open-sourced their CAD files and ROS interface for controlling the airship. They primarily use off-the-shelf components such as Raspberry Pi boards, propellers, a DC single brushed motor driver carrier, and LiPo batteries for a total cost of $90 for the platform, with an addition $20 for the balloon and initial helium filling. The price is comparable to the cost of indoor blimps like the Blimpduino 2.0.

You can check out the completed airship below, where the team demonstrates its path following capabilities based on a carrot chasing path finding algorithm. And if you’re interested in learning more about the gotchas of building lighter-than-air vehicles, check out [Sophi Kravitz’s] blimp talk from Hackaday Belgrade.

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