Every engineer interested in space research and innovation dreams of one day contributing to the development of global science. It often seems that such a goal is only achievable by a select few: talented scientists, large corporations, or employees of leading space agencies like NASA. However, in today’s world, thanks to global online platforms and open competitions, cooperation with such organizations has become real for anyone. Today, we’ll look at one example – a competition from NASA on the GrabCAD website called New Recuperator Design for the Cryogenic Fluid Management System and other opportunities for engineers, students, and enthusiasts to offer their ideas and join space projects.
The path to NASA is open to everyone
Many people think that developing for NASA or the European Space Agency (ESA) is a closed club where only the chosen few get in. But we have seen an increasing trend toward open competitions in recent years. In addition to GrabCAD, NASA cooperates with special platforms such as HeroX, Freelancer, and Topcoder, and organizes its challenges within the NASA Tournament Lab program. Similar initiatives can be found in other countries. For example, the U.S. Defense Advanced Research Projects Agency (DARPA) holds various technological competitions, from developing autonomous vehicles to creating complex robotic systems. All of this shows that the space and high-tech environment is becoming more open to “newcomers” who can bring fresh ideas.
Similar platforms also exist in Ukraine. Among the most famous are the Sikorsky Challenge and the Vernadsky Challenge by Noosphere, where talented Ukrainian developers compete in creating innovative projects. In addition, many universities and research centers participate in international programs such as the NASA International Space Apps Challenge, a global hackathon where enthusiasts look for solutions for projects related to space and environmental research. So, to join real global initiatives, you don’t have to be an employee of a space company, you just need to have a desire, research interest, and access to the Internet.
Opportunities and resources: where to find ideas and inspiration
One of the most important aspects of participating in such competitions is finding relevant information and reliable sources of knowledge. There are many resources available to improve your ideas and technical solutions:
- Academic and research bases: Google Scholar, IEEE Xplore, ScienceDirect. Here you can find articles and patents on cryogenic technology, heat transfer, design of innovative materials, etc.
- Online courses: Platforms like Coursera and edX offer specialized courses in thermodynamics, aerospace engineering, and 3D modeling. Some courses are free, others are available for a moderate price.
- Communities and forums: scientific and technical communities on Reddit (r/engineering, r/SpaceX, r/NASA), LinkedIn groups, Slack channels, and specialized GrabCAD forums. They help to discuss ideas and get quick feedback from an international audience.
All of this allows anyone – from a student to an experienced engineer – to actively develop and prepare for competitions where the main criterion is your knowledge and creativity, not formal merits or qualifications.
The essence of the competition Novel Recuperator Design for Cryogenic Fluid Management System
Let’s take a closer look at one of the current NASA competitions on the GrabCAD platform. Its name in the original sounds complicated – Novel Recuperator Design for Cryogenic Fluid Management System. Let’s analyze what is hidden behind this wording.
What are cryogenic systems? Cryogenic systems are systems that operate at very low temperatures (below about -150 °C or 123 K). In space, cryogenic systems include, for example, rockets and fuel storage facilities that contain liquid hydrogen, oxygen, or other cooled gases. Keeping the fuel in a liquid state is extremely important for missions, but in the vacuum and extreme temperature extremes of space, it is a major engineering challenge. Without proper cooling, the fuel will begin to vaporize (boil), which can lead to a loss of life and pressure.
The recuperator in a cryosystem is the heart of heat exchange. A recuperator is a heat exchanger that “returns” heat or cold to the system, increasing overall efficiency. In the case of a cryogenic recuperator, it is a device that transfers heat from a warm stream to a cold stream, or vice versa, as part of a cryocooler. Thus, the cold stream exiting the cooler absorbs heat from the warm return stream, cooling it before it is recycled. This increases efficiency, as less energy is used to re-cool the already pre-cooled gas. Recuperators come in different types; one of the most common in the industry is the shell-and-tube heat exchanger, where a bundle of tubes with one working medium passes inside a shell (casing) with another medium. In cryogenic systems, traditional shell-and-tube heat exchangers fulfill their role, but they have several disadvantages.
The challenge is that spacecraft have a very limited supply of resources: every gram of weight and every percentage of heat loss is of great importance. Developing the “perfect” recuperator is a search for innovative solutions at the intersection of thermodynamics, mechanics, materials science, and aerospace engineering.
Key challenges and potential solutions
Materials. At a temperature of 90 K (about -183 °C), most metals become brittle. The materials must be able to withstand cryogenic cooling without losing strength and have high thermal conductivity. Therefore, traditional metals (e.g., steel or aluminum) are not always suitable; sometimes special alloys or composites are used.
Tip: Look for information about “cryostable” materials in ASM International databases, and pay attention to temperature expansion and the behavior of materials during rapid heating/cooling.
Heat transfer and aerodynamics. Efficient heat transfer depends on the complex internal geometry of the heat exchanger and the flow rates. For cryogenic substances, there is the additional problem of ultra-low temperatures and the possibility of ice or condensation in certain areas. The recuperator must transfer maximum heat between the streams. An efficiency factor of >97% means that the device must be close to perfect heat transfer.
Tip: Use CFD (computational fluid dynamics) modeling to test different concepts. Programs like ANSYS or SolidWorks Flow Simulation can help in the early stages of design.
Sealing and safety. Liquefied gases are explosive under improper conditions. It is necessary to design the system taking into account the risks of leakage, overpressure, and thermal deformation.
Tip: Pay attention to the welding and soldering methods, the availability of leakage tests, and the impact strength of the materials.
Weight and dimensions. In space, every extra kilogram adds thousands of dollars to the cost of a launch. Therefore, lightweight and compact designs are often a decisive factor in the competition. The goal is to reduce weight and volume without sacrificing strength and efficiency. The competition has a target-specific power of ~100 W/kg, meaning that each kilogram of recuperator must transfer ~100 watts of heat flow.
Tip: optimize the geometry of the recuperator using topological analysis, and select “optimized” cross-sectional shapes.
Production. Even the best idea may not be practical if it cannot be implemented in real life. It is worth considering the availability of additive technologies (3D metal printing), CNC milling machines, casting, prefabricated structures, etc.
Tip: experiment with 3D printing, as complex internal channels in a recuperator can often only be realized using additive methods.
Frequently asked questions and answers
If you look at the discussions for this competition on GrabCAD, you can identify several frequently asked questions:
- Are there clear restrictions on size and shape?
The competition specifies approximate requirements, but most often, the organizers give some freedom. They advise to focus on real space missions. The main thing is to clearly describe and justify your design solutions. - What are the pressure and operating temperature requirements?
The technical brief usually specifies upper and lower temperature and pressure limits. If there is a lack of data, it is recommended to use typical parameters for liquid hydrogen (LH2) or liquid oxygen (LOX). For example, the operating temperatures could be -253°C (LH2) or -183°C (LOX). - What software can be used for modeling?
The competition does not limit the choice of programs, but ANSYS, COMSOL, SolidWorks, NX, and their modules for heat transfer are most often mentioned. It is important to set the material properties and boundary conditions correctly. - Is it acceptable to use non-standard materials?
Yes, organizers often encourage experimentation with advanced materials to unlock the full potential of innovation. However, it is important to describe the extent to which such material is available in production or at least theoretically feasible. - What are the evaluation criteria?
Usually taken into account:- Heat transfer efficiency (how quickly and with what temperature difference heat is transferred);
- Reliability and safety (tightness, resistance to pressure drops, reusability);
- Weight and dimensions (whether it is easy to integrate into a rocket and space complex);
- Innovativeness (how far the idea goes beyond conventional technologies).
Examples of other competitions and Ukrainian successes
In addition to the Novel Recuperator Design for Cryogenic Fluid Management System competition, there are other initiatives involving space and engineering solutions:
- NASA Space Apps Challenge: an annual global hackathon involving thousands of teams from different countries. Ukrainian teams have repeatedly reached the finals with projects related to environmental monitoring, satellite data processing, and drone interaction.
- Lunabotics: a competition dedicated to the development of robots for resource extraction on the Moon. Here, engineering students competed to create autonomous vehicles that could work effectively in the lunar soil.
- ESA Challenges: The European Space Agency organizes a number of challenges in robotics and small satellites (CubeSats). These challenges are often open to university teams and startups.
It is gratifying to note that our compatriots have already made a name for themselves in global competitions. Here are some inspiring examples:
Mars Hopper is a victory in NASA Space Apps 2016. A team from Kyiv has developed the concept of a Mars Hopper, a vehicle that jumps across the surface of Mars using CO2 as a propellant.
The NVS-knot is the winner of Space Apps 2024. By the way, the NASA Space Apps Challenge was regularly held in Ukraine. One of the main organizers of the local stage in Dnipro was the NGO Association Noosphere. It was thanks to their support that Ukrainian teams not only had the opportunity to join the global hackathon but also to win internationally. Their project is related to the use of Earth observation data for agricultural purposes. The competition was fierce: more than 90 thousand participants and 1000+ projects reached the NASA evaluation. And the Ukrainians won first place in one of the nominations, ahead of thousands of teams around the world. Read more about this success here.
Igor Nicol won a similar competition, GrabCAD, from Alcoa. Ukrainians are good not only at space tasks. In an open competition from Alcoa (an aluminum giant) on the GrabCAD platform, where it was necessary to create a lightweight and durable aircraft bracket, engineer Igor Nikol from Ukraine won first place among 316 participants from around the world.
Motivation for engineers: why you should dare
Participation in such competitions is not only a chance to win a cash prize or be recognized by NASA. It is, above all, an opportunity:
Deepen your knowledge. By working on a project, you improve your skills in thermodynamics, materials science, 3D modeling, project management, and teamwork.
Find a circle of like-minded people. Competitions bring together people from different countries and fields. The opportunity to collaborate with experienced professionals and scientists often leads to long-term cooperation in the future.
Get involved in real space programs. If successful, the development can be used as a basis for real missions or further research. All projects approved by NASA or other space agencies automatically receive high added value.
Contribute to history. Open competitions often become a launching pad for inventions that later change the industry. If your idea solves an urgent problem in space exploration, you will become part of a great story.
Doors open only to those who dare to knock.
Remember that NASA is not limited to the borders of one country and is always looking for people with an original approach and a new perspective on established technical challenges. If earlier it was necessary to work in a research center or have access to closed laboratories, today many ways to cooperate are opening up via the Internet. Don’t be afraid that your ideas are not so “grand” or that you don’t have enough experience: big projects always start with small steps, and independent participation in competitions is one of them.
So, if you have ever dreamed of getting closer to space, hurry up and take advantage of the opportunities offered by NASA, ESA, and other agencies. Today, it is a project of an innovative recuperator for a cryogenic system, and tomorrow, perhaps, your idea will become the basis for a Martian mission or help us look even deeper into the Universe. The main thing is not to stop on the way to your dream and to constantly improve in your chosen field.
