Printed heaters and battery monitoring for NASA's lunar rover: A FLEXOO case study

NASA, a leader in space exploration, faced a significant set of challenges in preparing their lunar rover for the extreme conditions of the Moon. The primary goal was to ensure the rover’s electronics and battery systems could maintain reliable performance in the deep space vacuum, where extreme temperatures threaten power stability and critical systems.

The challenges: Safeguarding and optimizing lunar operations

FLEXOO’s engineers were tasked with creating a robust, safe, and low-energy solution to address two key areas of concern for NASA's lunar mission:

Preventing electronics freeze-up: The most urgent task was to engineer a solution to safeguard the Lunar Rover's electronics from freezing during the extreme cold of lunar nights. Failure to maintain necessary temperatures risks shutting down vital systems and putting the entire mission in jeopardy. This required solutions that ensured precise temperature control in the harsh lunar environment.
Maximizing battery performance and durability: NASA sought a solution to not only ensure component protection but also to maximize system performance. A critical objective was to research and monitor battery behavior in the deep space vacuum, providing essential data for the success of future missions. This necessitated a system providing immediate access to sensor data for quick decision-making and critical insights into system integrity.

The FLEXOO solution: Turning challenges into opportunities

FLEXOO provided two cutting-edge solutions to meet these rigorous demands: self-limiting Positive Temperature Coefficient (PTC) heaters and its battery monitoring system BaMoS.

1. Engineering against the freeze with PTC heaters

To address the threat of extreme cold, FLEXOO provided a set of PTC heaters. These heating mats offer several key benefits for space applications:

Easy integration: PTC heaters are thin, flexible, and durable, allowing for easy integration into existing designs.
Safety and low voltage: The heating mats are designed to operate with low voltage and feature self-limiting capabilities, which ensures the safety of electronic systems.
Rigorous testing: The heaters, containing an anti-freeze solution, were provided for additional testing in a climate chamber set to extremely low sub-zero temperatures.

2. Maximizing performance with the BaMoS system

To meet the objective of researching and monitoring battery behavior, FLEXOO provided the BaMoS system. The system included the following features:

Real-time monitoring: The BaMoS system is designed to accurately measure the temperature and pressure distribution of pouch batteries within a vacuum environment. It enables real-time monitoring of pressure and temperature distribution within the battery pack, ensuring optimal performance and safety of the batteries.
Crucial data gathering: Gathering this data from battery tests is crucial for maximizing charging efficiency and understanding the behavior of pouch batteries during charging and discharging in a vacuum environment.

Feature	PTC heaters	BaMoS system
Primary function	Engineering against the freeze, and ensuring precise temperature control.	Research and monitor battery behavior in the deep space vacuum, and maximize battery performance.
Main objective	Safeguard the Lunar Rover's electronics from freezing during the extreme cold of lunar nights.	Accurately measure the temperature and pressure distribution of pouch batteries.
Physical characteristics	Thin, flexible, and durable.	Cutting-edge system enabling real-time monitoring.
Safety feature	Self-limiting capabilities.	Ensures optimal performance and safety of the batteries.
Operational detail	Designed to operate with low voltage.	Gathers data crucial for maximizing charging efficiency and understanding behavior during charging and discharging in a vacuum environment.

Features of FLEXOO’s solutions for NASA at a glance

Key outcomes of the FLEXOO solution for NASA

Protection and temperature control:

Challenge overcome: Preventing electronics from freezing during the extreme cold of lunar nights and ensuring precise temperature control in the harsh lunar environment.
Outcome (PTC Heaters): FLEXOO provided a set of thin, flexible, and durable PTC heaters with self-limiting capabilities. These heaters operate with low voltage and maintain necessary temperatures with minimal energy use, preserving battery life.

Battery monitoring and performance:

Challenge overcome: Maintaining reliable battery performance in the Moon's vacuum and delivering a system to research and monitor battery behavior in the deep space vacuum.
Outcome (BaMoS system): The cutting-edge BaMoS system was provided to accurately measure the temperature and pressure distribution of pouch batteries within a vacuum environment. It enables real-time monitoring, which provides critical insights into system integrity and helps maximize charging efficiency.

Overall mission safety and efficiency:

Challenge overcome: Minimizing energy consumption with a compact solution while ensuring safety and durability.
Outcome: The solutions collectively ensured the Rover's components function within safe parameters, enabling quick decision-making and adaptive responses during the mission, and providing essential data for the success of future missions.

Conclusion: Satisfying NASA’s demands

FLEXOO successfully delivered printed electronic solutions that ensured the rover’s components would function within safe parameters while simultaneously minimizing energy consumption. This work aligns with the mission of NASA’s Lunar Surface Innovation Initiative (LSII), which was established to bring together experts to cultivate new ideas and drive solutions for the productive exploration of the extreme lunar environment. By providing the self-limiting PTC heaters and the advanced BaMoS system, FLEXOO supported the safety and durability of the Rover’s electronics while providing critical insights for future deep space missions.

Who is FLEXOO and what do we do?

FLEXOO is a world leader in printed electronics. We provide services such as contract engineering and contract manufacturing. We also offer a wide range of solutions in the printed electronics spectrum, including: