Broad Area Cooling with Hybrid Additive Manufactured Pressure Vessel

Sierra Lobo, Inc. and our partner Big Metal Additive propose to design, build and test cryogenic liquefaction and storage tanks with Hybrid Additively-manufactured Tank-integrated CHannels for Broad Area Cooling (HATCHBAC) technology, a unique hybrid additive approach to manufacturing tanks with broad area cooling channels integrated directly into the walls of the tanks. This manufacturing approach has the potential to yield a smooth exterior surface over which a composite overwrap may be applied, minimizing system weight and maximizing efficient use of tank volume while maintaining structural strength. Unique tank shapes, only made possible with the use of hybrid additive techniques, can enhance propellant transfer capacity and maximize spacecraft packaging capabilities. The use of automated, computer-controlled machining also has the potential to minimize costs of manufacturing broad area cooled storage vessels, maximizing reproducibility while minimizing manual labor hours required to manufacture such tanks, and is easily scalable to larger tank sizes. Phase II thermal-vacuum testing will verify HATCHBAC thermal-fluid performance and predictions of the thermal model developed during Phase I. Phase II structural testing will include cold shock, proof pressure, and possibly a burst test to evaluate the mechanical and structural integrity of the hybrid additive thin-walled pressure vessel.