NASA Micro-G NExT National Finalist: AST-ROID Device

Project Overview: Contact Sampling Device NASA is preparing for the Artemis missions to the lunar south pole, where astronauts will collect geological lunar samples to study grain size, material variety, physical distribution, and grain orientation of the top regolith layer. To ensure pristine samples are collected and safely returned to Earth, a unique Contact Sampling Device is required for astronauts to collect a "contact sample" of lunar regolith, capturing the top 1-5mm of surface material and its grain orientation while avoiding contamination from EVA activities. The AST-ROID device features a glove-compatible operation, allowing easy sample extraction by scientists upon return, and is ergonomically designed for use in space suits, tested in the Neutral Buoyancy Laboratory (NBL) and Simulant Development Lab (SDL) at NASA's Johnson Space Center for optimal functionality and effective sampling.

My Role: Team Lead Co-led a group of 20 members, coordinating tasks, securing funding through grant proposals, and ensuring timely communication with NASA to meet project milestones. Also led the design and CAD development of the device, wrote and proofread our 50-page proposal, and organized team meetings to maintain project progress.

Design

  • Human Centered Design
    • Research
    • User Interviews
  • Solidworks
    • Sketching
    • CAD
    • Animation
    • Finite Element Analysis

Manufacturing

  • Rapid Prototyping
    • 3D printing (FDM/SLA)
    • Laser Cutting
  • CNC Machining
  • Assembly
  • Quality Control

Deliverables

  • 50 Page Technical Proposal
  • Meeting with NASA Technical Advisers
  • Progress Reports
  • NBL and SDL Testing at NASA JSC
  • Final Project Report

Key Outcomes:

  1. Selected by NASA as 1 of 3 National Finalist Teams

  2. Successfully co-authored $8,000 in grant proposals

  3. Wrote a 50 page proposal outlining the technical description and manufacturing plan for the AST-ROID sampling device

  4. Developed a functional CAD assembly with 25+ parts

  5. Hosted by NASA June 1-4 to professionally test our device at the Johnson Space Center NBL and SDL in Houston, TX.

AST-ROID Device Proposal

Provides an overview of the technical description of the design and operation of the contact sampling device, along with a thorough manufacturing plan. Additionally, it includes the outreach programs organized and hosted by the Columbia Space Initiative as a whole.

Stamping Device

  • This model utilizes a single linear motion to both collect the sample and securely store it for its return journey to Earth.

  • To comply with the Neutral Buoyancy Laboratory’s approved materials, we’re using Heptane glue. Heptane dissolves scotch tape adhesive, allowing it to be applied to any surface. The heptane evaporates, leaving a layer of adhesive that can be built up for custom thicknesses and shapes.

Handle

  • The hand grip features a triangular lip that provides an ergonomic surface for an EVA glove, allowing the fingers to curl around it and the palm to push down on the handle to activate the stamping device. A spring in the device returns it to its unactuated position, eliminating the need for the astronaut to pull or grip, which would be difficult in an EVA suit.

  • The handle is detachable, enabling quick swapping of multiple stamping devices for diverse sample collections. It also facilitates convenient storage of the entire device.

Pen Lock Mechanism

  • This system is inspired by the locking mechanisms in pens. With a simple push, a pin inserts into a hole that intersects two planes, securing them in place. Another push retracts the pin, allowing the planes to move past each other.

  • This mechanism serves two functions on the device: attaching and detaching the handle from the stamping device (top figure), and locking the device in both the actuated and unactuated positions (bottom figure with Stamp Cap Transparent). For example, the unactuated position provides stability when storing the collected sample, while locking the device in the actuated position ensures the sample plate remains secure, preventing tampering when freeing the plate.

Engineering + Design Process:

Sample Collection Ideation:

The first step was selecting the primary mechanism for sample collection. A key consideration was whether our device should be designed to collect multiple samples. Ultimately, our team decided to focus on perfecting single sample collection, which allowed the team to concentrate on refining the sampling mechanism itself, rather than dividing our attention between that and the process of rotating in a new sample plate.

Selected Collection Method: Self Inking Stamp

Our team modeled the sample device off of a self inking stamp as a way to collect and store the collected sample in one linear actuation, keeping an astronaut’s limited mobility in mind.

Sketches of Preliminary Ideas:

Final CAD Assembly:

Sample Plate Ideation:

Adhesive:

Collecting 1-5mm of regolith and preserving grain orientation for further surveying at the Simulant Development Lab are the primary functions of the heptane glue. The grains adhere and embed in a 500-micron-thick adhesive pad, ensuring both grain orientation and optical clarity are maintained as the particles depress into the adhesive. The heptane-adhesive solution enables the adhesive to mold to any shape, with the heptane evaporating afterward, leaving a precise layer of adhesive. This adhesion technique complies with NBL guidelines, utilizing a tape-like adhesive that is self-contained and cured. Furthermore, the adhesive is not water-soluble, making it suitable for use in the NBL environment. Using a CT scan of the sample plate, the grain orientation can then be accurately delineated for detailed surveying back on Earth.

Grain Orientation Preservation:

Sample Plate/Carriage Preliminary Sketches:

Sample Plate Attachment and Removal:

Our design consists of two main parts: the Sample Plate and the Carriage. The Sample Plate is designed to be easily attached and detached from the Carriage using two set screws. These screws thread into the two tapped prongs of the Carriage and press against the side of the two extruded rectangular prisms on the underside of the Sample Plate. The Carriage features two extruded complementary cutouts, which allow the Sample Plate to securely fit into place. This design ensures a stable connection between the Sample Plate and Carriage, allowing for easy handling and precise alignment.

CAD Sample Plate that Holds Adhesive+Collected Sample:

CAD Stamp Carriage (part that follows Stamp Track):

CAD Sample Plate + Carriage (transparent) Assembly:

Stamping Device from Underneath (ft. Sample Plate + Carriage):

Handle/Grip Shape Ideation:

Human Centered Design:

The handle of the ASTROID device is the component that the astronaut grabs onto and pushes down to actuate the stamping. When considering the handle for the ASTROID, it was imperative to find an alternative to smooth, round, rod-like hand grips that can cause fatigue to astronauts’ hands when using an EVA space suit glove. Therefore, our team avoided designs that would require additional gripping strength or excess dexterity.

Grip Shape:

For the handle grip, the team considered NASA’s Man-Systems Integration Standards for hardware and equipment and found a handle grip design with a one-hand triangular lip and recess. This design allows force to be applied using just the palm while the fingers are securely and comfortably held in the rounded-triangular lip which allows a bulky EVA suit glove to most efficiently grip the handle. Both of these design considerations minimize the motion needed in the fingers.

Attaching and Detaching Handle:

With the limited mobility of an EVA suit our team had to find a lock-and-release method suitable for these conditions. That is why the pen locking mechanism leveraging a simple push of a button is used to mitigate the need to grip objects.

CAD Handle:

Attachment to Stamp Device:

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