arXiv subjects

Khaled Gommed

Publications and source records attributed to Khaled Gommed.

5 recordsLinked to original sources

arXiv2026

Modeling the Thermal Behavior of Photopolymers for In-Space Fabrication

Future long-duration space missions will require in-situ, on-demand manufacturing of tools and components. Photopolymer-based processes are attractive for this purpose due to their low energy requirements, volume efficiency, and precise control of curing. However, photopolymerization generates significant heat, which is difficult to regulate in microgravity where natural convection is absent, leading to defects such as surface blistering and deformation. In this work, we combine experimental studies and modeling to address these thermal challenges. We report results from International Space Station (ISS) experiments and a dedicated parabolic flight campaign, which confirm that suppressed convective heat transfer in microgravity exacerbates thermal buildup and defect formation. Building on these observations, we present a predictive thermal model that couples heat transfer, light absorption, and evolving material properties to simulate polymerization and temperature evolution under terrestrial and microgravity conditions. Laboratory validation demonstrates strong agreement between model predictions and measured temperature profiles. Applying the model to the ISS experiments, we show that the model accurately reproduces experimentally observed blistering in TJ-3704A, a commercial acrylate-based polymer resin, while also predicting defect-free outcomes for Norland optical adhesives. The model functions as a design tool for defect-free in-space manufacturing, enabling selection of polymer properties, exposure strategies, and environmental conditions that together inhibit excess thermal buildup, paving the way for scalable, reliable in-situ manufacturing during future missions.

cond-mat.mtrl-sci↗

arXiv2025

In-space manufacturing of optical lenses: Fluidic Shaping aboard the International Space Station

In-space manufacturing technologies are vital for enabling advanced space missions and addressing logistical limitations of space exploration. While additive manufacturing has progressed rapidly, it still falls short of delivering the ultra-smooth surfaces required for optical elements. Fluidic Shaping is a novel method that harnesses surface tension under microgravity to form optical components with exceptionally smooth surfaces. This study demonstrates the feasibility and potential of Fluidic Shaping as a method for manufacturing optical components in space through two experiments performed aboard the International Space Station (ISS) during the Ax-1 mission. The first experiment involved fabricating centimeter-scale polymer lenses, solidifying them via ultraviolet (UV) curing, and analyzing the resultant optics upon their return to Earth. While sub-nanometric surface smoothness was achieved, some polymer lenses displayed unexpected thermo-chemical deformations, indicating complex polymerization dynamics unique to the microgravity environment. In the second experiment, a large-scale, 172 mm diameter water lens was deployed, confirming Fluidic Shaping's scalability and demonstrating basic optical functionality through image analysis. These experiments collectively underline the technique's relevance for both small-scale optics and large-aperture applications. Our results highlight critical considerations for future research, including optimizing polymerization processes and refining liquid-handling methods to advance practical, in-space optical manufacturing capabilities.

physics.optics↗

arXiv2022

Fluidic Shaping and in-situ Measurement of Liquid Lenses in Microgravity

In the absence of gravity, surface tension dominates over the behavior of liquids. While this often poses a challenge in adapting Earth-based technologies to space, it can also provide an opportunity for novel technologies that utilize its advantages. In particular, surface tension drives a liquid body to a constant-mean-curvature shape with extremely smooth surfaces, properties which are highly beneficial for optical components. We here present the design, implementation and analysis of parabolic flight experiments demonstrating the creation and in-situ measurement of optical lenses made entirely by shaping liquids in microgravity. We provide details of the two experimental systems designed to inject the precise amount of liquid within the short microgravity timeframe provided in a parabolic flight, while also measuring the resulting lens characteristics in real-time using both resolution target-imaging and a Shack-Hartmann wavefront sensing. We successfully created more than 20 liquid lenses during the flights. We also present video recordings of the process, from the lenses creation during microgravity and up until their collapse upon return to gravity. To the best of our knowledge, this is the first time that a purely liquid lens has been created in microgravity, which demonstrates the feasibility of creating and utilizing liquid-based optics in space.

physics.optics↗

arXiv2022

Programmable thermocapillary shaping of thin liquid films

We present a method that leverages projected light patterns as a mechanism for freeform deformations of a thin liquid film via the thermocapillary effect. We developed a closed-form solution for the inverse problem of the thin-film evolution equation, allowing to obtain the projection pattern required in order to achieve a desired topography. We experimentally implement the method using a computer controlled light projector, which illuminates any desired pattern onto the bottom of a fluidic chamber patterned with heat absorbing metal pads. The resulting heat map induces surface tension gradients in the liquid-air interface, giving rise to thermocapillary flow that deforms the liquid surface. If a polymer is used for the liquid film, it can then be photocured to yield a solid device. Based on the inverse problem solutions and using this system, we demonstrate the fabrication of several diffractive optical elements (DOEs), including phase masks for extended depth of field imaging, and for 3D localization microscopy. The entire process, from projection to solidification, is completed in less than five minutes, and yields a sub-nanometric surface quality without any post-processing.

physics.optics↗

arXiv2018

Elastohydrodynamics of a pre-stretched finite elastic sheet lubricated by a thin viscous film with application to microfluidic soft actuators

The interaction of a thin viscous film with an elastic sheet results in coupling of pressure and deformation, which can be utilized as an actuation mechanism for surface deformations in a wide range of applications, including microfluidics, optics, and soft robotics. Implementation of such configurations inherently takes place over finite domains and often requires some pre-stretching of the sheet. Under the assumptions of strong pre-stretching and small deformations of the lubricated elastic sheet, we use the linearized Reynolds and Foppl-von Karman equations to derive closed-form analytical solutions describing the deformation in a finite domain due to external forces, accounting for both bending and tension effects. We provide a closed-form solution for the case of a square-shaped actuation region and present the effect of pre-stretching on the dynamics of the deformation. We further present the dependence of the deformation magnitude and timescale on the spatial wavenumber, as well as the transition between stretching- and bending-dominant regimes. We also demonstrate the effect of spatial discretization of the forcing (representing practical actuation elements) on the achievable resolution of the deformation. Extending the problem to an axisymmetric domain, we investigate the effects arising from nonlinearity of the Reynolds and Foppl-von Karman equations and present the deformation behavior as it becomes comparable to the initial film thickness and dependent on the induced tension. These results set the theoretical foundation for implementation of microfluidic soft actuators based on elastohydrodynanmics.

physics.flu-dyn↗