Description: Demand for novel technologies for space systems brings unique properties of bulk metallic glasses (BMG) into the spotlight. In addition to superior mechanical properties associated with enhanced reliability, BMG technology can offer new manufacturing processes that result in components with higher precision and complexity, eliminating machining and minimizing the final assembly. In this project, we propose to utilize the unique thermoplastic forming (TPF) ability of BMGs to net shape high precision robotic gears. Within Phase I and Phase II, we have demonstrated feasibility of the technology and advanced it to a level that allowed fabrication of complex BMG robotics gears that were successfully tested by NASA. The technical objectives for Phase II-E is to increase the TRL level of the technology to level 6 and produce flight-ready BMG components for strain wave gears for JPL/NASA COLDArm project using TPF processes. In order to achieve this, we need to improve part quality and thus its performance. During Phase II-E, we plan to use a new high-pressure forming equipment built during Phase II. We will optimize the processing conditions and protocols of the high-pressure TPF process to entirely suppress the undesirable crystallization and to produce fully amorphous BMG flexsplines that can be used by NASA for various space missions, including COLDArm project. Beyond space applications, the use of versatile thermoplastic forming processes for precision gears has a strong potential to bring an enhanced performance and cost savings for a wide range of industries that use robotic mechanisms.

Benefits: Advanced manufacturing of complex, high precision functional parts with superior mechanical properties is critical for NASA. We aim to develop and produce precise and complex robotics gears using thermoplastic forming of BMGs. BMGs have high strength, elasticity, fracture toughness, hardness and wear resistance. Additionally, they maintain these properties down to cryogenic temperatures and in harsh environments. Thermoplastically formed BMG gears are highly promising for space application and will be used in COLDArm Project and other missions.

BMG robotics gears can also be used for industrial and consumer robotics. Overall, thermoplastic forming of BMGs will offer unique opportunities for robotics, space applications, aerospace, defense, automotive and biomedical industries. BMG technology is expected to bring significant benefits in terms of superior properties and efficient processing technologies in these industries.