Thermal

Thermal

Overview

We’re leaders in the creation and installation of Thermal blankets and other innovative thermal products. These custom thermal products are used in flight missions and critical environmental testing. Blankets are insulation implemented as a means of passive thermal control for aerospace satellites in a range of thermal environments ranging from high temp to cryogenic. We also engineer and build Deep Space Radiator Simulators (DSRS) along with Active and Passive Q-meters to help create and carefully measure your thermal test setups.

We design and then create templates or patterns of your thermal products to assure that we establish the best design for your MLI needs. We will also work with you to bring your design to life through use of C.A.D or drawings you provide.

DESIGN

FABRICATION

INSTALLATION

Genesis Thermal Fabrication Team is comprised of highly skilled and experienced specialists. Using approved design templates, Thermal Products are hand crafted to comply with industry design and quality standards. Our Certifications and training in Integration Operations makes us a valuable part of a program’s Integration Team. The same specialists that are involved with the MLI design and fabrication see the product through to completion at installation ensuring design integrity.

Services

  • Multi-Layer Insulation (MLI)
  • Single-Layer Insulation (SLI)
  • Design
  • Templating
  • Fabrication
  • Installation
  • Bake Out Coordination/Support
  • Integration and Test Support
  • Launch Site Support

Consulting

  • Material Assessments
  • Grounding and Venting Schematics
  • Special Design Accommodations
    • Field of View
    • Glint and Glare
    • Deployables
    • Moving Parts
    • Atomic Oxygen
  • Mechanical Fasteners

Types of MLI and SLI

  • Cryogenic / Layer-by-Layer Build
  • High Temperature
  • Instruments
  • GSE / Test and Environmental
  • Flight and Flight Spares
  • Flight Simulators
  • Engineering Models
  • Shielding
    • Light Block
    • Thermal
    • Micro-Meteorite
    • RFI / EMI
  • Sewn Construction
    • Overlays
    • Velcro
    • Pouches
    • Soft Products for ISS (International Space Station)

Products

  • Applied Thermal Coatings
    • ITO (Indium Tin Oxide)
    • SiOx (Silicon Oxide)
    • VDA (Vapor Deposited Aluminum)
    • Silver Teflon Tapes
  • Gasket Fabrication
    • CHO-THERM®
    • CHO-SEAL®
    • eGRAF®
    • Indium
  • Passive Q-meters
  • Active Q-meters
  • DSRS

Composites

Composites

Overview

In recent years we have partnered with offsite partners to build our innovative composite design solutions. These products have overcome mass restrictions and harsh cryogenic environmental conditions such as Deep Space Radiator Simulators for testing on the JWST program and isolation systems for the International Space Station. Our engineers’ past experiences range from unmanned aerial systems like the Global Hawk to the Orion Spacecraft.

Current Work

Currently our engineers are working on the WFIRST high stability optical composite structure. Working in partnership within NASA teams, we’re developing lower risk solutions to composite joints.

What are your needs? We have the experience to deliver a working composite solution fully tested to the toughest standards. We have the resources to design, test, and build a composite solution for you.

Examples of Composite Structures

James Webb Space Telescope (JWST)

The ISIM Electronics Compartment (IEC) utilizes many unique composite features:

— Shell (fiberglass, nomex core, rohacell, carbon weave)

— Radiator Panels (aluminum core, facesheet, inserts

— Baffle Mirrors (fiberglass, carbon fiber, vapor deposited gold)

Composite Panel Build

— Aluminum Honeycomb core for lightweight bus structures with a variety of composite face sheet materials

— Radiator Panels (aluminum core, facesheet, inserts)

— DSR (Deep Space Radiators) Deep space thermal simulator

Innovative Composite Solutions

— Lightweight spring loaded hinge solution

— Hollow beam structure and joint solutions

— Custom form fit light weight containers for fragile equipment delivery to ISS(Canadarm for example)

Mechanical

Mechanical

Overview

Our Mechanical team works closely with Project Management and our Thermal, Electrical, and Optical teams to create informed and collaborative designs. From proof-of-concept development and prototyping, to full environmental testing and flight integration, our experienced personnel know what it takes to meet our unique industry needs.

Mechanical Product Examples

  • Flight Hardware (with supporting documentation and certifications)
  • Advanced Calibration, Characterization, and Alignment systems
  • Ground Support Equipment (GSE)
  • Flight Spare and flight like test hardware simulators
  • Positive pressure testing blast containment containers

Common GSE

  • Lift slings
  • Vibe and model test fixtures
  • Transportation dollies
  • Cold plates
  • Beam Image Analyzer (BIA)

Q-Meters

Often, when high quality thermal correlation is needed, it is necessary for a thermal balance test to yield both temperature and heat flow results. Genesis has extensive experience designing, building, and calibrating high accuracy heat flow measuring devices called Q-meters, which can be incorporated into a thermal balance test set-up to greatly enhance thermal measurement capability.

DSR (Deep Space Radiator)

A DSR is an extremely high-emissivity plate. As it is cooled to approximately 17 K it provides for the test article a flight-like thermal environment. Genesis has developed a unique manufacturing process for the DSR technology. Genesis efforts supported critical verification testing to document the emmissive properties over a range of temperatures.

Space Avionics

Space Avionics

Overview

Our class 100K avionic lab houses a skilled manufacturing team backed by experienced designers. We utilize board layout design software and a wide range of equipment.

Our Equipment

  • Automated Stencil Printer
  • Wave Solder Machine
  • Electrovert OmniFlo
    10-Hot Gas Reflow Oven
  • Mycronics Automated Pick and Place
  • Aqueous Cleaner
  • Conformal Coat Equipment
  • Rehm Thermal System
  • CondensoXS Vacuum
  • Condensation Soldering System
  • Circuit Card Assembly(CCA) Lamination
  • Class Zero Workstations
  • Lead Forming and Tinning
  • Forced Hot Gas Rework Station
  • NIST Calibration Requirement

Genesis is licensed to produce and market the NASA GSFC SpaceCube 2.0 design, GEN6000, which utilizes reconfigurable processor technology.

Our end-to-end Space Avionics capabilities include the following demonstrated circuit card processes which meet all NASA requirements:

Surface Mount Technology

  • Leadless Chip Carriers
  • Ball Grid Array (1760)
  • Column Grid Array (1760)
  • Chip Capacitors/ Resistors
  • TSOP & Flatpack
  • Lamination Process
  • 2 PWBs Mounted to Heatsink
  • Hypertronics cPCI Connectors

Avionic and Electrical Certifications

  • IPC J-STD-001– Space Addendum to IPC J-STD-001 Requirements for Soldered Electrical and Electronic Connections
  • NASA-STD-8739.3 – Soldered Electrical Connections
  • NASA-STD-8739.4 – Crimping, Interconnecting Cables, Harnesses and Wiring
  • NASA-STD-8739.1 Polymeric Application and Inspection
  • NASA-STD 8739.1 Mate/Demate connector training
  • 300-PG-8730.6.1 ESD Control Plan
  • Cleanroom
  • Confined Space

Electrical

Electrical

Overview

We’re known for the quality and innovation of the custom Electrical Hardware we build for the aerospace industry. Our manufacturing team fabricates flight hardware, and equipment for critical ground support testing.

We also offer clients our Counterfeit Detection Program which uses an XRF Machine to detect counterfeit components and prohibitive materials to ensure they’re receiving reliable parts.

Whether your design needs to be built-to-print, or your concept flows from our electrical design team, your electrical hardware will be custom fabricated to NASA aerospace standards.

Electrical Products

  • Flight Hardware
  • Harness and Cables with supporting documentation and certifications
  • Test Racks
  • Custom Breakout Boxes and Cables

Electrical Capabilities

Design

  • Flight and non-flight harnessing
  • Electrical Ground Support Equipment (EGSE) interface boxes and equipment racks
  • Simulators
  • Data acquisition equipment

Fabrication

  • Flight and non-flight harnessing
  • Electrical Ground Support Equipment (EGSE) interface boxes and equipment racks
  • Simulators
  • Data acquisition equipment

Integration

  • Harness Layout
  • Harness Integration

Test

  • Harness
  • Electronics box
  • Electrical Ground Support Equipment (EGSE) Certification
  • Flight electronics procedure generation and implementation

Documentation

Includes End Item Data Package complete with As Built Test Verifications such as High Pot and Continuity Testing

Deliver

  • Hand carry delivery
  • insured shipping or integration as appropriate

Current Electrical Project Support

Ocean Color Instrument Plankton Aerosol Cloud ocean Ecosystem (OCI PACE)
James Webb Space Telescope (JWST)
Radar for Europa Assessment and Sounding: Ocean to Near Surface (REASON)
Multi Angle Imager for Aerosols (MAIA)
On-orbit Servicing, Assembly, and Manufacturing (OSAM) 1
X-ray Imaging and Spectroscopy Mission (XRISM)
(formerly XARM)

Procurement

Procurement

Our rapid, results-based, efficient team handles all your purchasing, obtaining best pricing via multiple bids. If you have been frustrated with slow responses in your material and parts sourcing, we work diligently on your behalf to identify sources that fit your priorities and meet your delivery needs. Our team focuses on providing solutions-minded, project-oriented service that often results in our customer’s receiving their product in hand before other competitors provide a quoted cost.

Purchase Options

Here are just a few ways we can serve you with procurement:

  • Build-To-Print (via Custom Manufacturing Vendors)
  • Large-Item and Long-Leadtime Procurements
  • Space Qualified Electrical, Electronic and Electromechanical (EEE) Components (Microcircuits, Relays, Resistors, Caps, Relays, Transformers, Connectors, Contacts, etc.)
  • COTS Hardware/Software
  • Printed Wire Boards (PWB)
  • Custom Precision Machined Parts
  • Custom Sheetmetal Parts
  • Weldments
  • Composites
  • Fasteners

Environmental Test

Environmental Test

State of the Art Test Equipment

Your engineered flight hardware can be environmentally tested using our state of the art test equipment and service support. Our friendly and knowledgeable staff can support you with test plan development, test configuration set up, instrumentation and real time monitoring and adjustments.

Our Dynavac Thermal Vacuum Chamber and Sentek Shaker table are perfect for instrument and small component environmental testing (see their technical specs here). You can also meet your contamination requirements using out TVAC chamber for bake outs complete with outgassing data provided by our RGA and QCM measurements.

Thermal Testing

  • Test Development and Planning Instrumentation
  • Standard GSE (Mechanical, Thermal, & Electrical)
  • Advanced Custom Cryogenic GSE (DSERS & QMeters)
  • Post Test Analysis
TVAC Technical Specs

Vibration Testing

  • High & Low Level Sinusoidal Vibration
  • Random Vibration

Vibration Table Specs

Acoustic Testing

  • Acoustic frequency response
  • Data Processing
  • Post Data Analysis
Note: We support this testing offsite at GSFC. We arrange for the testing and support the data processing along with post data analysis.

Modal Testing

  • Test article support
  • Verify response frequencies and modes
  • Free vibration response
  • Post Analysis Reports
Note: We support this testing offsite at GSFC and will arrange for testing and support the reports.

Mechanical Testing

  • Static Loading
  • Deflection
  • Data Processing
  • Analysis and Results
  • Impact

Facilities

Facilities

SERVICES

State of the Art

Genesis is conveniently located less than 15 minutes from NASA Goddard Space Flight Center and houses modern manufacturing and design operations within in a beautifully maintained 35,000 square foot facility.

More than a building, our facility is a vital part of how we can support you. We provide flexible rental options that give your team the room and the tools to dream, create and test.

From a cleanroom for flight integration activities to basic desk space and conference rooms, we have room at our facility to support your project team.

Directions to the Genesis main facility.

2,300 square foot
class 10K clean room

Harness fabrication lab

Electronics manufacturing lab equipped with state of the art machines

Blanket fabrication lab

Open high bay
with movable clean tents

Environmental testing area (TVAC Chamber and Vibration Table)

Specs on TVAC Chamber
Specs on Vibration Table

Conference room for team meetings