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VibraVoid – Vibration Avoidance with Acoustic Black Holes in Spacecraft

VibraVoid – Vibration Avoidance with Acoustic Black Holes in Spacecraft

In the space industry, random structural vibrations and shock loads pose significant design challenges, often causing fractures in brittle components, joint slippage and failure of sensitive electronics. New countermeasures to control vibrations are therefore essential. This project explores an innovative approach using a phenomenon similar to black holes to reduce vibration in lightweight space structures.

Special structures known as Acoustic Black Holes (ABH) cause sound waves to disappear in narrow regions. Studies show that ABHs can reduce vibrations by 30 dB with a mass saving of 26%. Integrating ABHs into aerospace structures involves creating dents or cross-sectional reductions combined with damping material. ABHs are ideal for lightweight structures and can be applied to satellites, launchers or rovers.

The project aims to develop a technology demonstrator of a space structure with integrated ABHs. Ultimately, the technology will be transferred to other industries, due to ABHs’ wide range of applications.

Benefits:

  • Reduction of random structural vibrations in space structures
  • Lightweight structure with up to 26% mass saving potential
  • Wide range of spin-off transfer applications, e.g. for the automotive industry

VibraVoid
Fraunhofer LBF, OHB Systems AG
Nikolai Kleinfeller
nikolai.kleinfeller@lbf.fraunhofer.de

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AGREE – Avoiding Greenhouse Gas Emissions in Rare Earth Element Production by Transferring Space Resource Technology to Earth

AGREE – Avoiding Greenhouse Gas Emissions in Rare Earth Element Production by Transferring Space Resource Technology to Earth

Extracting metals from ores is essential for our technological society, but it requires enormous amounts of energy and is responsible for 40% of global greenhouse gas (GHG) emissions. Perfluorinated hydrocarbons (PFCs), potent GHGs, are emitted in the production of rare earth metals, which are indispensable for electromobility, magnets and high-performance alloys. Europe currently imports 98% of these metals, posing geopolitical risks.

For the extraction of Oxygen from lunar regolith (“moon dust”), an Airbus led consortium developed ROXY (Regolith to OXYgen and metals conversion), a GHG-free electrolysis process that is ideal for metals with a high affinity for oxygen and hard-to-reduce oxides. AGREE is adapting this process for Earth, focusing on the rare earth elements scandium and neodymium.

The project will optimise key components such as electrodes and demonstrate efficient, PFC-free production of Sc and Nd from their oxides in the laboratory. It will also include the design of future scaled-up facilities and the establishment of industrial partnerships to scale up sustainable production of rare earth elements.

Benefits:

  • Contribution to an independent rare earth metal value chain in Europe
  • Reduction of greenhouse gas emissions for a sustainable rare earth element production
  • Technology transfer of electrolysis technology originally developed to extract oxygen and metals from lunar regolith

AGREE
Fraunhofer IFAM,
TU Bergakademie Freiberg,
Airbus Defence and Space
Dr Georg Pöhle
georg.poehle@ifam-dd.fraunhofer.de

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StellarHeal: Wound Healing in Space and on Earth

StellarHeal: Wound Healing in Space and on Earth

StellarHeal tackles the unique challenges of wound healing in space, where weightlessness and radiation affect wound closure, putting astronauts’ health at risk. The solution includes a special silica gel padding, enriched with cryopreserved cells, and a protective gel. The silica gel is resistant to radiation and flexible enough to fit different wounds, with a coating that helps to stop bleeding quickly. The added cells – cryopreserved fibroblasts and macrophages – promote smooth healing and fight infection, making it perfect for space missions.

StellarHeal combines several advanced developments into a novel application. It aims to improve medical practice and the economics of wound care, and has significant potential for future applications both in space and on Earth. The consortium combines expertise in materials science, cryotechnology and biotechnology to develop, deploy and adapt the solution for various medical and biotechnological applications.

Benefits:

  • Enables rapid and improved wound closure in microgravity to prevent wound infection
  • Protects wounds from the adverse effects of radiation exposure
  • Prevents severe wound scarring
  • May address chronic wound healing for patients on Earth

StellarHeal
Fraunhofer ISC, Fraunhofer ITEM, ILK Dresden
Dr Dieter Groneberg
dieter.groneberg@isc.fraunhofer.de

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FERROTHERM

INNOspace_label_results-dlr3_2022

FERROTHERM

FERROTHERM

“Moon Village” is considered one of the most important projects of manned space flight. However, the long-term energy supply for the urbanisation of the Moon has not yet been clarified. Temperatures vary between -170 °C and +120 °C, and solar energy is unavailable during the two week long moon nights. There are no fossil fuels on the Moon. The energy supply must be secured with lunar regolith, a mixture of different metal oxides. Current storage systems, such as batteries, heat accumulators or mechanical storage units, lack the capacity for long-term supply. The Fraunhofer IST and ICT are developing a process by which metallic iron can be extracted from regolith and used as a non-fossil fuel. Unlike fossil fuels, the combustion products are solid and can be collected. They are recycled in a novel process and can be reused. The unique solution uses a direct electrochemical process to recycle the iron oxide in order to produce iron again, bypassing the previously known hydrogen route. This makes the process very efficient. It operates at temperatures below 100°C. The process can be used terrestrially in modified power plants or combined heat and power plants and thus makes a significant contribution to climate protection (decarbonisation).

Benefits:

  • Circular economy
  • Time-independent energy supply (day/night) on the Moon
  • Iron fuel is extracted from lunar regolith
  • On Earth, the process makes an important contribution to decarbonisation
  • Combustion products are recycled by means of excess electricity

Fraunhofer IST
Dr Andreas Dietz
Andreas.Dietz@ist.fraunhofer.de
ist.fraunhofer.de

Fraunhofer
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Aerostructure Multifunctional Cover Against Environmental Radiation

INNOspace_label_results-dlr2_2022
INNOspace_label_results-overall_2022

Aerostructure Multifunctional Cover Against Environmental Radiation

3 AeroMulE_Pitchdeck_INNOspace Masters 2022

We all increasingly use communication networks, including Wi-Fi, mobile phones, satellite networks, Internet of Things, autonomous driving, and monitoring in medicine and the environment. People, as well as machines, will become more and more connected wirelessly. Therefore, the number of antennas integrated into electronic devices is drastically increasing, resulting in strong demand for countermeasures against unwanted signals and noise. Until now, typically metal-based materials have been used to shield electronics. While these are very secure, they are intrinsically very heavy. Moreover, the antennas themselves cannot be covered, as they would then no longer be able to transmit signals. We aim here to drastically reduce the weight of such shields by employing an ultra-lightweight class of materials, called framework aero materials. We will develop small, innovative safety caps that are easy to apply, without being a barrier to the further miniaturization of electronic devices. This new kind of cap will also enable frequency selectivity, thereby increasing the digital security of communication.

Benefits:

  • Ultra-lightweight cover against unwanted  signals
  • Increase in digital security and protection against jamming
  • Frequency-selective: antennas can be protected
  • Very adaptable for specific geometries without mounting interfaces
  • High frequency tightness
  • Wide range of applications at different value-added levels

Institut für Luft- und Raumfahrttechnik der Technischen Universität Dresden
Dr Tino Schmiel
tino.schmiel@tu-dresden.de
Institut für Materialwissenschaften der Christian-Albrechts-Universität zu Kiel
Dr Fabian Schütt
fas@tf.uni-kiel.de

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PFDS – Pre-Ignition Fire Detection System

INNOspace_label_results-dlr1_2022

PFDS – Pre-Ignition Fire Detection System

Downward burning of the Saffire V sample at 60kPa_40O2

Fire on board inhabited spacecraft or habitats on the Moon or Mars is one of the greatest conceivable hazards. Fires are currently detected exclusively by smoke detectors. Due to the weightlessness in orbit, they are prone to frequent false alarms triggered by non-sedimenting dust, while the preferred direction of smoke propagation is slowly towards the life-support system’s intake. In addition, smoke detectors can principally only detect an existing fire situation and, in the omnipresence of dust on the Moon, they can no longer be expected to function reliably. The new PFDS approach detects potential fire sources based on off-normal thermal outgassing of materials, e.g., volatile organic components from plastics or fabrics, in the cabin air. The semiconducting metal oxide sensors do not react to specific gases, but react to alterations in the overall composition of the air. Trained by applying machine-learning methods, they can reliably recognise alarming composition patterns. The method has already been successfully used to survey underground high-voltage power lines. It also has great potential for improved detection of terrestrial fires – ideally long before they break out.

Benefits:

  • Detection of potential fire sources even before ignition occurs
  • Proven principle
  • Low-cost components (for terrestrial application)
  • Easy installation
  • Wide range of applications

Universität Bremen,
Zentrum für angewandte Raumfahrttechnologie und Mikrogravitation, ZARM
Christian Eigenbrod
Christian.Eigenbrod@zarm.uni-bremen.de
zarm.uni-bremen.de

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SpaceFlow

INNOspace_label_results_2021-3rd DLR

SpaceFlow

SpaceFlow

Energy security plays a major role for satellites and space stations due to their isolated places of operation. Since solar energy is often used to operate these spacecraft, reliable energy storage systems are crucial to compensate for fluctuations in direct solar radiation. These storage systems need to have a very long service life as well as a high operational safety in order to sustainably reduce resource-intensive replacement missions as well as hazards for humans and equipment. However, the battery systems currently used in spacecraft have significant deficits in these areas. That’s why, with »SpaceFlow«, a new energy storage concept for space applications is being presented, which completely fulfils the requirements. »SpaceFlow« is an incomparably long-lasting, charge-cycle-stable, safe and reliable redox flow battery system based on porous metal foam electrodes and zinc-polyiodide electrolytes. The innovative design allows the pressure-stable yet flexible battery cells to be integrated directly into the spacecraft support structures, so that, in addition to energy storage, other functions such as module stiffening or thermal management can be realised with an efficient use of space.

Benefits:

  • Very long service life and theoretically unlimited cycle stability
  • Particularly high operational safety and environmentally neutral cell chemistry
  • Very efficient use of space with multiple applications

Fraunhofer Institute for Environmental,
Safety, and Energy Technology UMSICHT
Jan Girschik
jan.girschik@umsicht.fraunhofer.de
www.umsicht.fraunhofer.de

All winners
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TOMOPLEX – A sensor film to monitor structures during flight and under a load

INNOspace_label_results_2021-2nd DLR

TOMOPLEX – A sensor film to monitor structures during flight and under a load

INNOspace_Broschuere_2020-2021-2nd DLR

Only reusability ensures cost-effectiveness in order to be able to operate the space sector in line with “New Space”. However, the possible saving in costs is limited by maintenance requirements. Some faults also only occur under a load, but remain hidden during inspections without a load. One example of this is break lines, which fit together perfectly in an unloaded state. A comprehensive installation of measuring probes to monitor structures during flight is not currently feasible, as the conventional measuring technology required for this is too large and heavy. The problem of needing to monitor structures in real time has now been resolved by creating a version of the sensor as a sensor film that can be applied to the surfaces of the structures undergoing monitoring. It is possible to use alternative measuring procedures and, in particular, electric impedance tomography (EIT) here, which has been uncommon in the aerospace sector up to now. The sensor film acts as the circuit carrier for a wireless sensor network. The sensor film is space-saving and flexible, and can also be used in hard-to-reach areas.

Benefits:

  • Continuous real-time monitoring under a load during flight
  • Increase in the likelihood of reusability
  • Reduced costs due to optimised maintenance with the aid of innovative analysis data

Julius-Maximilians-Universität Würzburg
Alexander Hilgarth, Prof. Sergio Montenegro
alexander.hilgarth@uni-wuerzburg.de
sergio.montenegro@uni-wuerzburg.de
www.uni-wuerzburg.de

Universität Würzburg
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QuVeKS – quantum processors for encrypted communication with satellites

INNOspace_label_results_2021-1st DLR

QuVeKS – quantum processors for encrypted communication with satellites

INNOspace_Broschuere_2020-2021-1st DLR

Novel quantum technologies of the 21st century promise unconditionally secure communication, exponentially larger computational power as well as compact and more precise sensors. Many of the quantum systems under investigation, however, are application-specific and not compatible with each other. Within the QuVeKS project, a universal quantum processor will be developed at the Friedrich-Schiller-Universität Jena and the CiS Forschungsinstitut für Mikrosensorik. This processor integrates the entire architecture, from the quantum light source to the detectors, into a compact circuit and can be universally programmed just like a computer chip for various applications. The project places a special focus on secure communication with satellites, as the QuVeKS chip can be used as a light source for quantum cryptography during daylight. Moreover, compared to conventional laser-based systems, the data rates can be enhanced drastically. In the long term, end-user devices such as smartphones or computers could also be equipped with such a QuVeKS chip, where it could be used as a secure random number generator or as a sensor.

Benefits:

  • Secure communication based on the laws of nature
  • Higher data rates compared to laser-based systems
  • Flexible use cases through universal programming
  • Future standard component with local supply chain

Institute of Applied Physics,
Friedrich-Schiller-Universität Jena
Dr Tobias Vogl
tobias.vogl@uni-jena.de
www.iap.uni-jena.de

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HOSSA

INNOspace_label_results_202025

HOSSA

Space Launch System Takes Off. 3D Scene.

Fraunhofer IISB is developing a novel technology for ultra-high-temperature resistant protective coatings for space applications. The HOSSA project is based on the institute’s research work to apply ceramic protective coatings to fibre-reinforced composites using powder coating technology.
The aim is to make the advantages of fibre-reinforced composite components, such as high elongation at fracture, high cracking resistance and dynamic load capacity, available for new applications by increasing heat and oxidation resistance as well as increased mechanical abrasion resistance. The patented technology offers a considerable cost advantage over conventional coating processes and is also suitable for component repair.
With HOSSA, the efficiency of propulsion systems and the exposure time for re-entry vehicles can be increased. These protective coatings can also be applied for power units of aircraft and helicopters as well as gas turbines.

Benefits:

  • Highly tuneable coating technology to achieve different coating properties
  • Cost-effective and highly flexible in terms of part geometry and size
  • Enables the application of fibre-reinforced composites in new applications
  • Higher combustion temperatures and thus increased efficiency of rocket engines and power units

Fraunhofer Institute for Integrated Systems and
Device Technology IISB
Erlangen, Germany
Dr-Ing. Christian Reimann
christian.reimann@iisb.fraunhofer.de
iisb.fraunhofer.de

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