Browse Topic: Test facilities
Rocket Lab Corporation Long Beach, CA
With unprecedented capabilities for simulation and artificial intelligence, the Aurora supercomputer at the U.S. Department of Energy’s (DOE) Argonne National Laboratory is helping researchers explore new ways to design more efficient airplanes.
For decades, Sandia National Laboratories’ National Solar Thermal Test Facility has harnessed the power of the sun to expose aerospace materials to intense heat, replicating the harsh conditions of faster-than-sound flight and atmospheric reentry to ensure the materials’ ability to protect the rest of the vehicle. The most recent of these tests is in support of two exciting NASA missions.
Additive manufacturing, or 3D printing, is a new way of making metal parts and other types of materials by building them layer by layer. This research project, by researchers at General Electric, the Edison Welding Institute, and Oak Ridge National Laboratory (ORNL), printed an alloy composed of Inconel 718 and René 41 at two ends with a compositional graded region in the middle. The study evaluated the stress and composition variations of the alloy. To do so, the researchers conducted neutron experiments at the Spallation Neutron Source (SNS) and the High Flux Isotope Reactor (HFIR) at ORNL, both Department of Energy Office of Science user facilities. Neutrons are ideally suited to study internal stresses in materials because they can penetrate dense metals.
This SAE standard establishes the requirement for suppliers to plan a reliability program that satisfies the following three requirements: a The supplier shall ascertain customer requirements b The supplier shall meet customer requirements c The supplier shall assure that customer requirements have been met
This paper presents the contributions of the Royal Netherlands Aerospace Centre (NLR) to a Leonardo-led consortium participating in NATO Next-Generation Rotorcraft Capability (NGRC) Study #5, which is aimed at the development of Integrated Platform Concepts (IPC) to fulfill the NATO NGRC 2035+ Capability Development needs. NLR contributed to this industry effort by providing an independent evaluation of the high-speed tiltrotor concept proposed by the consortium led by Leonardo, considering aspects such as handling qualities, rotorcraft-ship compatibility, as well as a broader operational Battle Lab assessment. The handling qualities assessment and related control law development considered predictive metrics from ADS-33E and MIL-1797A, and yielded Level 1 handling for the baseline tiltrotor concept along with an evaluation of design sensitivities. The ship compatibility assessment, based on in-airwake trim and simulated lateral approach procedures, offered early insight into tentative limits for tiltrotor shipboard operations on Frigate-class navy vessels. The Battle Lab simulations provided an early holistic evaluation of operational effectiveness of the proposed IPC in the Air Assault mission scenario that is part of the NGRC Concept of Operations (CONOPS).
This organizational process survey provides insight into the technical aspects of approved airworthy aircraft modifications applied in government organization vertical lift flight test. The publication reviews processes applied by the National Research Council of Canada's Flight Research Laboratory (NRC-FRL) and its Airworthiness Control System to enable research flight testing. Dominated by the need for integrating experimental payloads, the NRC-FRL embeds a Design and Fabrication Service organization for modification of internal and external client projects and flight test aircraft. In context of experimental flight testing, this work reviews technical information on process, facilities, and methodology for airworthy integration of flight test payloads. Information is used to synthesize recommendations in experimental vertical lift flight testing that satisfy both formal (regulated compliance) and informal (compliance intent) airworthiness requirements.
This work presents the development of an interconnected gearbox drive system for a tandem rotor unmanned aerial vehicle (UAV) designed for a power rating of 20 kW per rotor. Development of the facility for dynamic testing of the interconnecting drive system is also presented. Tandem rotor configurations offer superior payload capacity and aerodynamic efficiency but pose challenges in transmission design due to the need for synchronized power distribution between counter-rotating rotors. The proposed gearbox employs a simple two-stage reduction system combining bevel and planetary gears to achieve compactness, high torque transmission, and ease of fabrication. A dedicated test rig is concurrently being developed to evaluate gearbox performance under variable torque and speed conditions for the first stage with the mechanical interconnection. The test set-up integrates a variable-speed drive, torque and vibration sensors, and a data acquisition system to measure efficiency, losses, and thermal characteristics. While fabrication and assembly are ongoing, this work lays the foundation for experimental validation and optimization of drivetrain performance. The project contributes toward developing reliable, lightweight, and scalable transmission solutions for heavy payload multi-rotor vertical lift UAVs. The drive system dynamics, in particular, the torque transmission through the cross shaft during maneuvers will be the investigated using the current test rig configuration.
Army researchers recently developed a 3D-printable, easy-to-assemble drone designed to enhance intelligence, surveillance and reconnaissance capabilities. Army Research Laboratory, Adelphi, MD Researchers at the U.S. Army Combat Capabilities Development Command, or DEVCOM, Army Research Laboratory (ARL) harnessed bottom-up Soldier innovation to develop an experimental 3D-printed small unmanned aerial system, or drone, that was demonstrated at the inaugural U.S. Army Best Drone Warfighter Competition in Huntsville, Alabama. Known as the Soldier Portable Autonomous Reconnaissance Transitioning Aircraft, or SPARTA, the drone was developed at DEVCOM ARL in collaboration with Soldiers. By incorporating Soldier feedback early in the design process and leveraging ARL's world-class research facilities, researchers developed a 3D-printable, easy-to-assemble drone designed to enhance intelligence, surveillance and reconnaissance capabilities. ARL is actively working to partner the technology with industry to get into the hands of the warfighter.
Researchers at the U.S. Army Combat Capabilities Development Command, or DEVCOM, Army Research Laboratory (ARL) harnessed bottom-up Soldier innovation to develop an experimental 3D-printed small unmanned aerial system, or drone, that was demonstrated at the inaugural U.S. Army Best Drone Warfighter Competition in Huntsville, Alabama.
A team of researchers from the U.S. Department of Energy Ames National Laboratory developed a magnetocaloric heat pump that matches current vapor-compression heat pumps for weight, cost, and performance. Current heating and cooling devices are based on vapor-compression technology, which is over 100 years old. They rely on refrigerants that contribute to global carbon emissions, and when they leak the chemicals are harmful to people and the environment.
Researchers at Lawrence Livermore National Laboratory (LLNL) have optimized and 3D-printed helix structures as optical materials for Terahertz (THz) frequencies, a potential way to address a technology gap for next-generation telecommunications, non-destructive evaluation, chemical/biological sensing and more.
Air Force Research Laboratory (AFRL) Wright-Patterson Air Force Base, OH
Machina Labs recently closed its latest round of financing with $124 million, enough to develop a facility featuring up to 50 of its RoboCraftsman cells capable of producing thousands of complex structural assemblies for aerospace and defense customers - a list that already includes Lockheed Martin and the U.S. Air Force, among others. Founded in 2019, Machina Labs is a California-based company that seeks to reinvent metal manufacturing with a robot that uses artificial intelligence (AI) to rapidly form and assemble complex military grade structures directly from digital design files. RoboCraftsman is the company's manufacturing robot that leverages its proprietary “RoboForming” process to integrate multiple manufacturing processes - including metal forming, trimming, scanning, and heat treating - into a single containerized machine.
As the utilization of lithium-ion batteries in electric vehicles expands, monitoring the usable cell capacity (UCC) is essential for ensuring accurate state-of-health (SOH) estimation. Battery performance degradation is influenced by temperature and constraints. Capacity tests in laboratory settings are typically conducted at low C-rates to approximate equilibrium conditions, whereas in real vehicle applications, charging currents are often much higher. This discrepancy in rates frequently results in deviations between laboratory characterization and on-board Battery Management Systems (BMS) capacity estimation. To investigate how C-rate of diagnostic Reference Performance Test (RPT) modulates aging effects under temperature and mechanical loading, we conducted long-term cycling tests on lithium iron phosphate/graphite pouch cells at 25°C and 45°C under different constrained conditions. The cycling protocol is a tiered multi-rate protocol. Cells were aged at Block1 under 1C, and UCC evolution was quantified after each block. The result shows battery aging can be divided into three stages: a decelerated, steady, and accelerated aging stage. The degradation of LFP cells is dominated by loss of lithium inventory (LLI), and elevated temperature accelerates the degradation. By combining differential voltage analysis (DVA), direct current internal resistance, electrochemical impedance spectroscopy, and ultrasonic testing, we found that under 45°C free condition, accelerated aging is consistent with intensified SEI growth and electrolyte decomposition, accompanied by increased LLI, gas-generation, and increased resistance. These signals emerge earlier than the apparent capacity divergence and may serve as early indicators for predicting the onset of rapid degradation. Appropriate constrain mitigates aging, and its influence becomes more pronounced when using higher-rate RPTs. At 25°C, high-rate RPTs exhibit an apparent capacity recovery. DVA analyses indicate the recovery originates from gradual activation of lithium. Overall, these findings illustrate and explain the degradation characteristics and capacity recovery phenomenon, providing a reference for connecting laboratory standard tests with on-board BMS capacity estimation.
Leonardo DRS has opened a new naval power and propulsion manufacturing and testing facility in Charleston, South Carolina, expanding its role in delivering next generation electric propulsion, integrated power systems, and high energy payload support for U.S. Navy surface and undersea platforms. The 140,000 square foot site consolidates advanced manufacturing, final assembly, and high fidelity testing for electric power conversion and propulsion systems, while also supporting naval steam turbine design, production, and subsystem integration for programs including the Columbia class ballistic missile submarine. A representative for Leonardo's Naval Power Systems business unit provided emailed statements with details about the type of advanced manufacturing the company will deploy at the new facility.
A team of engineers at the University of California San Diego has developed an electronic sticker that can monitor a person’s vitamin C levels using the sweat from their fingertips — no blood draws, lab visits, or batteries required. The flexible sticker, which attaches to the outside of a drinking cup, collects trace amounts of sweat as a person grips the cup. Within minutes, the system harvests enough power from the sweat to analyze it for vitamin C and wirelessly sends the results to a nearby laptop. The device was published in Biosensors and Bioelectronics.
New research from Argonne National Laboratory and the University of Chicago Pritzker School of Molecular Engineering has solved a major battery mystery that has led to capacity degradation, shortened lifespan and, in some cases, fire.
Robotic biomanufacturing company Multiply Labs recently announced a landmark milestone in its mission to scale production of cell and gene therapies. The company is now leveraging NVIDIA’s open Isaac and GR00T technologies including advanced robotics simulation and perception, marking a turning point for an industry that has historically relied on manual, “artisanal” processes.
Jet Propulsion Laboratory Pasadena, CA
When the Empire State Building was constructed, its 102 stories rose above midtown one piece at a time, with each individual element combining to become, for 40 years, the world’s tallest building. Uptown at Columbia, Oleg Gang and his chemical engineering lab aren’t building Art Deco architecture; their landmarks are incredibly small devices built from nanoscopic building blocks that arrange themselves.
NASA’s Space Communications and Navigation (SCaN) Program and the Johns Hopkins Applied Physics Laboratory in Laurel, Maryland, have successfully tested wideband technology that allows spacecraft to communicate with both government and commercial networks for the first time.
NASA's Space Communications and Navigation (SCaN) Program and the Johns Hopkins Applied Physics Laboratory in Laurel, Maryland, have successfully tested wideband technology that allows spacecraft to communicate with both government and commercial networks for the first time. Launched July 23, 2025, aboard a SpaceX Falcon 9 rideshare mission, the Polylingual Experimental Terminal (PExT) is demonstrating multilingual wideband terminal technology. Hosted on a satellite from York Space Systems, PExT enhances a spacecraft's communications subsystem, enabling mission controllers to track and exchange data more efficiently across a broad range of networks and frequencies.
This study examines the capability of medium-fidelity comprehensive analysis models to predict the acoustics for manned and unmanned rotorcraft configurations. Using the automated tool NDARC2RCAS developed at DEVCOM Army Research Laboratory, multiple configurations including a single main rotor, tilt rotor, coaxial and pusher, quadcopter, and hexacopter are evaluated at various mission segments including hover, advancing climb, and forward flight. Each configuration and condition is evaluated using a range of aerodynamic models from lower to higher fidelity, including uniform inflow, dynamic inflow, prescribed wake, free wake, and viscous vortex particle method (VVPM). These evaluations are then used with another automated tool, RCAS Acoustics, to predict noise on a Voronoi observer sphere. A comparison of the results for the single main showed good agreement between all of the aerodynamic models except VVPM. For the tilt rotor in forward flight, the higher-fidelity models produced changes in rotor loads due to the interaction with the wing. With prescribed and free wake models, this change in load is sharp and causes noise increases of up to 40 dB in front of and behind the vehicle, while the VVPM model produced a smoother change that results in a smaller, 20 dB increase in noise. The quadcopter and hexacopter show similar in-plane noise levels for all models, with alternating cancellation and amplification patterns due to rotor phasing, while out-of-plane noise is increased on the hexacopter when using the higher fidelity models.
Penn State UAS Research Lab (PURL) and Autonomous Robotics Competition Club (ARCC)
Higher road noise is perceived in the cabin when the test vehicle encounters road irregularities like bump or pothole in the public roads. The transfer of transient road inputs inside the body caused objectionable cabin noise. Measurements are conducted at different road surfaces to identify the patch where the objective data well correlated with the noise measured at the public road. Wavelet analysis is carried out to identify the frequency zones since the events are transient in nature. TPA is carried out in time domain to identify the nature of the noise and the dominant path through which the transient road forces are transferring inside the body. Based on the outcome of TPA, various countermeasures like reduction of dynamic stiffness of suspension bushes, TMDs on the path are proposed to reduce the structure borne noise. Criteria which need to be considered for reduction of cabin noise due to transient road inputs is also discussed.
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