Onken, Jay

Singer, Christopher E.

NASA Technical Reports Server

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National Aeronautics and Space Administration 
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Cutting More Than Metal: 
Breaking the Development Cycle 
 
AIAA Propulsion and Energy Forum 2014 
July 28-30, 2014 
Christopher Singer, 
Director of Engineering 
Jay Onken, 
Deputy Chief Engineer, Space Launch System 
https://ntrs.nasa.gov/search.jsp?R=20140012584 2019-08-31T18:07:51+00:00Z
Learning from the Past, Not Living by it 
8583_Singer_Onken.2 
Capability for a New Era of Space Exploration 
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Development Culture vs. Operational Culture 
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Changing the Design Process 
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Additive Manufacturing 
SLM Exhaust Port Cover for J-2X 
(inset and position on engine) 
3-D printed rocket injector for hot fire test 
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Structured Light Scanning 
Training  and implementing 
technique with industry. 
J-2X nozzle extension showing 
deformity data projected onto part. 
8583_Singer_Onken.7 
Shell Buckling Knockdown Factor Testing 
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Wind Tunnel, Adaptive Algorithm Testing 
F/A-18 tests for SLS flight control 
3-D printed rocket injector  
for hot fire test 
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Hardware in the Loop Testing 
Test engineer runs  avionics flight 
simulation in SITF. 
Workers set  up SLS avionics in SITF 
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Core Stage Manufacturing 
First Core Stage confidence barrel 
section at MAF 
First Core Stage confidence dome 
section at MAF 
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Path to First Flight 
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Results 
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www.nasa.gov/marshall  
 
Questions? 
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Explorers Heart: Courage, Passion, Curiosity 
Tragedy triggers our opposing desire to control uncertainty 
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New Technologies Will Never Entirely Replace Testing 
A-3 Test Stand in Background, 
Engine and Photographers in 
Foreground 
Engine 2308 Incident 
SSME 2013 In the Spillway 
Downstream of the Flame Detector 
Immediately After Test 901-364 
HPFTP Turbine Kaiser Hat Failure 
8583_Singer_Onken.16 
NASA Before PowerPoint 
The physics are the same. How we communicate has changed. 17 
8583_Singer_Onken.17 
Tools and Techniques to Manage Risk 
8583_Singer_Onken.18 
NASA Programs are Tied to Administration Cycles 
Direction and Redirection Come Every 4 to 8 Years 
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Inspiration for Generations 
20 8583_Singer_Onken.
21 
Ares Development Team Observations 
We made incredible progress despite many obstacles 
•  Growing constraints, hurdles, and attitudes in an  
attempt to finish something … anything  
•  Decisions take too long and are unsupported 
•  “Death” by meetings and PowerPoint 
•  Proliferation of Ineffective Working Groups,:  
All voices are equal and no one is in charge 
•  One-chance development philosophy  
(no block upgrade or early testing strategy) 
•  Technical is disconnected from Cost & Schedule  
(Engineering vs. Project);  
•  Subsystem stovepipes (everybody for themselves) 
•  Pounding issues flat 
J-2X Operation 
J-2X Development 
J-2X Design 
Uncertainty Can Help Feed Innovation 
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Past Present Future What is changing? 
Design Design is becoming more integrated with 
manufacturing, shortening the product  life cycle 
and reducing overall cost. Minimizes re-design, 
re-work. 
Analysis Computers are getting faster, memory is getting 
cheaper, leading to higher resolution analytical 
models. Analytical models are becoming more 
fully integrated. 
Producibility, 
Modeling and 
Simulations 
The transition from paper drawings to 3D design 
models and associated modeling and 
simulations have enabled advanced producibility 
analysis with great savings. We are also working 
towards using annotated models in place of 
drawings. 
Manufacturing Transitioning from manual processes to full 
automation, CNC milling, additive processes. 
 
Inspection and 
Test 
Transitioning from discrete measurements to 
structured light scanning,  more full inspection 
coverage and the ability to compare “as built” 
directly to “as designed” models, reducing 
inspection time and increasing fidelity. 
Logistics and 
Operations 
 
Using 3D virtual simulations in addition to 
drawings to reduce cost and schedule by 
evaluating interfaces during the initial design 
phase. Simulations can significantly increase 
efficiency and preparedness for operations. 
 
Labelçç ActualX ActualY ActualZ I J K 
C_DEVICEPOS001             
M_PLANE001 0.3453 -0.0139 0 0 0 -1 
M_CIRCLE001_I 0 0 0 0 0 -1 
M_LINE001 5.6373 0.7553 0       
C_COORDSYS001 0 0 0 0 0 1 
C_ALIGNMENT001             
M_POINT001 53.7429 37.9456 6.738 0 0 0 
M_POINT002 65.2972 -6.3056 6.5745 0 0 0 
M_POINT003 61.493 -11.345 -18.992 0 0 0 
M_POINT004 -53.105 -38.714 6.5737 0 0 0 
M_POINT005 -64.651 7.4137 6.4737 0 0 0 
M_POINT006 45.5545 -7.5359 73.7245 0 0 0 
M_POINT007 48.788 -9.274 94.8781 0 0 0 
M_POINT008 47.4436 -15.478 120.66 0 0 0 
C_DEVICEPOS002             
M_POINT009 -27.913 34.1752 73.1477 0 0 0 
M_POINT010 -29.465 35.413 96.2339 0 0 0 
M_POINT011 -32.774 37.0945 120.437 0 0 0 
C_DEVICEPOS003             
M_POINT012 -30.539 -32.851 73.3956 0 0 0 
M_POINT013 -30.42 -36.051 96.2743 0 0 0 
More Automation 3D models are carried 
through all phases of the 
product life cycle. 
8583_Singer_Onken.22 


Cutting More Than Metal: Breaking the Development Cycle

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