Description: DSTAR Communications proposes to implement the new fiber manufacturing process on board the International Space Station (ISS) to mitigate the challenges of environmental sensitivity and brittleness of exotic fiber materials. The proposed Microgravity-Enhanced Molten-Core Optical Fiber (MEMO Fiber) development encapsulates the challenging crystal and glass fiber structures inside environmentally stable and mechanically strong outer cladding glass. The Phase I SBIR study defines the optimal outer cladding materials for scalable fiber production on the ISS. The most promising core-cladding combinations with the best commercial and scientific value are optimized for manufacturing in space and produced in sample quantities on the ground. The goal of the Phase II development is to establish a debris-free MEMO fiber manufacturing process, pass the safety reviews and fabricate MEMO fibers on board of the ISS. The scalability of the MEMO fiber manufacturing will be further developed with the goal of kilometer-length fiber production runs on the ISS. The processing of MEMO fibers will be optimized to demonstrate vitrification and crystallization of the core materials. The samples of new MEMO fibers will be delivered to NASA and provided to the key industry partners for setting up Phase III sustainable manufacturing plans of MEMO products in space.

Benefits: The new molten-core fiber manufacturing in combination with microgravity-enhanced processing targets sustainable optical fiber manufacturing in space. Advanced encapsulation enables vitrification and crystallization studies of the new materials. The advanced probes will improve new propulsion development, space vehicle assembly and in-space reliability characterization of aging space assets. The broadband infrared fibers will deliver new opportunities for orbital debris characterization, remote atmospheric studies and exoplanet search.

The new fibers would benefit automated quality control for critical paints and coatings across multiple industries, from semiconductor processing to automotive manufacturing and aerospace assembly. The capture of temperature and infrared spectrum is essential for the multi-billion-dollar endoscope and medical instrumentation market, environmental monitoring and critical infrastructure management.