Digitally analysing and reconstructing space shuttles

10 October, 2007

Since the return to flight after the Columbia disaster in 2003, the software has been a major part of the process that enables NASA to detect, assess and repair, if necessary, tile damage caused by foam particles dislodged from the shuttle and other space-borne debris.

Capturing, processing and digitally recreating tiles for the shuttle starts with a Neptec scanner mounted on a 50ft long extension of the shuttle’s robot arm. As the shuttle nears the space station it rolls over – video surveys and detailed 3D scanning inspections are then conducted to determine damage to the tiles under the wings.

Scan data from the system is transmitted to NASA then sent to Boeing engineers in Houston, where Geomagic Studio is used to process the data and create a 3D digital model of the damaged tiles. These files are then imported into CATIA software to create a final model which enables Boeing to conduct thermal, stress and other analyses as required. Boeing is the major subcontractor to United Space Alliance, NASA’s prime contractor for space shuttle operations. Automated processes in Geomagic Studio enable Boeing to transform scan data into accurate digital surface models in around ten minutes per scan.

The digital models were also used to create rapid physical prototypes of the damage for analysis and possible repair simulation. The analysis showed that the Endeavour’s damage was not extensive enough to call for a spacewalk for astronauts to make the repair.