SBIR-STTR Award

Relatively small concentric thin film FRESNEL lenses and fresnel-like Multiple Parabolic Reflecting Surface (MPRS) reflectors have been successfully produced from molds machined with diamond turning lathes, which are limited in size to less than 15 feet diameter. This size limitation prevents using this fabrication method for production of molds for operational size space concentrators and off-axis (non-concentric) patterns cannot be produced at all with lathes. UAT has been demonstrated that computer numerical control (CNC) milling machines that can readily machine complex geometries, including any radius of curvature, can be used to produce mold segments representing any portion of any size MPRS. These mold patterns can then be replicated on thin film sheets, which are then appropriately integrated to produce solar concentrators of the desired size. Multiple focal lengths/points, concentration ratios, and controlled flux distribution can be incorporated in a single reflector panel allowing substantial and previously unavailable Wireless Power Transfer System design flexibility. The Phase I program will verify the thin film performance capabilities and scalability of the MPRS concept and the Phase II program will provide a full scale concentrator applicable to Wireless Power Transfer technology for testing and deployment.

Long duration space missions and extended manned missions on the surface of the moon and Mars are key elements of NASA's new Vision. These missions will require utilization of in situ resources and materials to reduce up-mass and up-volume and for fabricating habitable structures from in situ materials. The overall objective of this Phase II is to design and fabricate an in situ materials processing solar furnace system using the flat panel thin film MPRS concentrator technology successfully developed during Phase I. The capability of this system will be demonstrated by realistically processing lunar regolith simulant into useful product specimens such as fiberglass rods for structural reinforcement and bricks for habitat construction.The technology foundation established in Phase I, which demonstrated unprecedented solar concentrator design and performance versatility, combined with UAT's extensive experience in designing and fabricating thin film concentrators and lightweight deployable structures, provides a sound basis to project that this objective can be achieved.