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Completed TRL 2 (started at 2, targeting 4)
Project Objective
Develop and demonstrate a modular smart sensing system using intrinsic piezoresistive materials and multiplexed grid instrumentation to detect, locate, and characterize structural damage on lunar hardware, enhancing crew safety and mission resilience.
Project Description
The goal of this TID was to quantify the change in resistance and the development of a deployable instrumentation configuration that could be integrated into future space/Surface Systems. Additionally, the sensing grid could be adapted as a sensory skin technology for non modular systems. Future efforts would entail partnering with EM42 to integrate concept into composite sheets with embedded conductive paths and further testing on large-scale structures. "Develop manufacturing approaches and design implementation for future space applications
As humanity sets its sights on establishing sustainable habitats on the lunar surface, ensuring the safety and longevity of these habitats becomes paramount. Among the numerous challenges posed by lunar habitation, protection against Micro-Meteoroid Orbital Debris (MMOD) and lunar regolith debris resulting from rocket propulsion emissions may emerge as critical concerns. This EV43 TID aims to tackle the challenge of safeguarding lunar habitat exterior walls by passive integrating intrinsic smart structure detection technologies. Concurrently; it strives to alleviate one or more of the Marshall Space Flight Center (MSFC) shortfalls/gaps by leveraging detection methodologies developed within the EV43 SHARC Lab. This concept will implement an intrinsic smart structure based around the detection of damage of non-linear and homogenous structural panels. Where each of the materials selected has inherent electrical conductivity. Academic research in intrinsic smart structure technology has shown that these properties can be used to detect damage within the structure via the variability in resistance or capacitance. Currently there are limitation to detecting location and scale of damage. Current ongoing research heavily focuses on Artificial Intelligence (A.I.) training of specific panels requiring upfront significant computation resources. The M-AEGISS TID plans to integrate smart structure methodologies and use a time division multiplexed grid search detection system to identify panel damage location; severity and type. These unique material traits could be leveraged in the future development of structures that pose an innate capacity for structurally smart functionality such as lunar habitat walls within a cosmic environment. For example, such a system may be capable of monitoring the structural health of the outer and inner bumper layers of a lunar base Whipple shield that may undergo hypervelocity impact (HVI) penetrations from debris (20-72 km/sec).
Project Results and Conclusions
In calendar year 2025, the M-AEGISS TID team at NASA MSFC achieved several key milestones in the development of a piezoresistive-based damage detection system for carbon fiber composites. A prototype sensing grid was successfully designed and integrated into composite panels using RTD cards and matrix switching, enabling repeatable resistance measurements at 16 distinct locations per panel. This system demonstrated the ability to detect and localize damage from ballistic impacts, validating the concept of resistance-based structural health monitoring. The panels were constructed using T1100G/3960 prepreg materials with a layup tailored to match transit habitat designs, ensuring relevance to future mission architectures.
Hardware fabrication and testing were conducted in collaboration across multiple MSFC departments, including EM41 for impact testing and EM42 for panel builds. The project advanced from TRL 2 to TRL 4, with data confirming that resistance changes correlate with damage severity. Lessons learned included the importance of consistent electrode contact, the potential benefits of embedded electrodes over edge contacts, and the need to account for environmental variables such as temperature and radiation in future iterations. Additionally, the team identified opportunities for expanding the sensing grid and applying AI-based visualization techniques to enhance real-time damage assessment.
The project remained within budget and met its initial objectives, laying the groundwork for future innovation efforts. The technology shows promise for integration into Mars transit vehicles and lunar surface habitats, with ongoing work aimed at refining the system for real-time fault detection and crew safety assurance. Plans are in place to present findings at the 66th MSFC Jamboree and pursue publication to share results with the broader aerospace community.
Anticipated benefits of this technology include accelerated identification and localization of structural damage in composite panels, which enables more timely and efficient maintenance procedures. The system enhances analytical capabilities for characterizing and quantifying damage severity through high-resolution resistance measurements, contributing to improved structural assessment and operational decision-making. Validation using space-rated composite materials ensures applicability to future exploration missions, including Lunar and Martian surface systems. The underlying sensing methodology demonstrates potential for broader implementation in terrestrial domains such as aerospace, automotive, and civil infrastructure, where real-time structural health monitoring can support risk mitigation and system longevity.
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