SATOP Success Story Catalog -2024

Table of Contents

What is SATOP?

Texas Alliance Partners

What is an Alliance

Partner?

AlliancePartnersareaerospacecompanies,academicinstitutions,andNASA JohnsonSpaceCenterthatprovidethetechnicalexpertisetothesmallbusinessesparticipatinginSATOP.

Technical Assistance Map

Throughoutthelifetimeoftheprogram,from 1999 to present,SATOPhasassistedmore than 1,100 businesseslocatedalloverthe StateofTexas.Withtheassistanceprovidedto thesebusinesses,SATOPhasgeneratedan economicimpactof over 200 million dollars.

Texas Success Stories

Infant Transporter Incubator—Texas Children’s Hospital

Texas Children’s Hospital (TCH) set out to reduce the potentially hazardous effects of the vibrations to the incubator used to transport super premature infants to specialized care hospitals. The engineers at NASA Johnson Space Center (JSC) analyzed the shock and vibration imparted to the infants while they were being transported by helicopters and ambulances. The NASA JSC engineers and TCH are working to implement a shock and vibration dampening system that will smooth out the ride for these fragile babies. (RTA 2361)

Paraffin Deposits in Oil Well Pipes Jerry Hawken

Jerry Hawken developed a system – A Therminol System – that prevents paraffin solidification inside of oil well tubing. NASA Johnson Space Center engineers, Brian Lusby and Pooja Desai, recommended a preheating period prior to pumping. Once the annular region becomes heated, it allows the Therminol System to maintain oil production tubing at temperatures higher than the cloud point, preventing paraffin deposits from forming. (RTA 3871)

NFL Football Helmet Chin Strap SportStar Athletics

SportStar, a manufacturer of high-quality athletic equipment, wanted to enhance the design of a football helmet chin strap by reducing irritation caused by the strap. SPACEHAB evaluated the design on the chin strap and recommended a modification to the chin strap that eliminated the sharp protrusion. With SATOP ’s help, SportStar identified the best plastic for the helmet strap and removed the sharp angle in the strap design. Additionally SportStar has received recommendations from SATOP to improve snaps located on the side of football helmets to increase the life of the chinstrap and to replace hardware that releases the chinstrap in order to increase the safety of athletes. With these improvements, SportStar is now one of the most popular providers for the NFL serving the Super Bowl, Stanley Cup, World Series, and college football playoffs. (RTA 3945)

High Pressure Thermoplastic Pipe Smart Pipe

Steve Catha, director, International & Special Projects, developed a high pressure reinforced thermoplastic pipe. The pipe is meant to restore the degraded pipeline to its full pressure service rating and renew the projected service life of the degraded pipeline to like new or better. Steve Catha was seeking help in joining sections of reinforcement materials from one spool to another without stopping the production line. SATOP’s Alliance Partners were able to solve this challenge and provide Steve Catha with viable recommendations. (RTA 3716)

Unmanned Aerial Vehicle Mission Technologies, Inc. Mission Technologies, Inc., developed an Unmanned Aerial Vehicle system. When the Department of Defense became interested, Mission Technologies had to decrease the launcher’s overall size and weight. NASA Johnson Space Center engineers analyzed the launcher and deduced that the two designs the company had developed were too large, too heavy, and put too much stress on the aircraft. They improved the interfaces, reduced the weight and size of the launcher, and developed a prototype that reduced the weight from 35 to 10 pounds, allowing Mission Technologies to meet the requirements set out by the Department of Defense. (RTA 49)

Mosca Boat—Mosca Custom Boats

Mosca Custom Boats designs quality boats with simple layouts, quiet hulls, and many standard options. The boats are built of composite materials for strength and buoyancy and the company needed cost effective materials to bond fiberglass shells to the hull of the boats. The Corpus Christi Hispanic Chamber of Commerce directed Mosca Boats to SATOP for technical assistance. SATOP matched the company with Alliance Partner Composite Factory, Inc., which examined the materials used by Mosca Custom Boats and recommended adhesive options that utilize different bonding mechanisms. With SATOP’s assistance, Mosca Custom Boats implemented one of the recommendations, thereby reducing manufacturing costs. (RTA 1379)

Truck Safety Wheel—Sheldon Container

Sheldon Container’s Richard Hanson developed a concept design for an external wheel that would be mounted on the exterior of the front wheel of commercial trucks to provide emergency control in the event of a blowout or deflation. His initial concept was to use a solid aluminum-formed wheel with a solid rubber outer portion, which would extend to the outside of existing front wheels. Jacob’s engineer Satish Reddy conducted structural analyses of the original design, concluding that the original concept would deform upon impact. Reddy redesigned the wheel concept as a pneumatic tire to reduce stress during the initial moments of a blowout, which would also allow for the wheel to be used more than once. With this new design, Sheldon Container was able to contact potential venture capital partners in order to secure funding for manufacturing and marketing of the invention. (RTA 3835)

Zeno Acne Treatment Zeno Corporation

Zeno Corporation developed Zeno a product designed to clear up acne. The company required an improved heating element that would meet specifications and be simple and inexpensive to produce. The Boeing Company was instrumental in leading the company in the right direction toward designing a new heating element, reducing the cost of the heating element from around $85 to less than $1. Zeno Corporation subsequently received Food and Drug Administration approval and began manufacturing of the product. The product is currently sold nationwide in Walgreens and other retail outlets. (RTA 818)

Lawrence Aviation Services, LLC

James Lawrence of Lawrence Aviation Services LLC, developed a novel wing design for general aviation aircraft. He sought help from SATOP to confirm claims made in the patent application. Alliance Partner San Jacinto College ’s professor Nathan Wiggins and his students developed a three -dimensional CAD model of the wing. The model was subjected to flow simulations. After simulations, Nathan Wiggins and his students designed a wing that allowed airflow into it to determine the changes in air motion and overall lift. Lawrence was provided with a 3D model of the wing that he is able to open on any computer and work with. (RTA 3876)

Airline Oxygen Cargo Container Texas Calibration

Texas Calibration developed a small cargo container to transport oxygen cylinders and generators on cargo and commercial airlines. The company needed help in identification of a material to build a shipping container that could withstand temperatures of 1700 degrees F for several minutes. SPACEHAB, Inc., provided materials recommendations and eventually formed a partnership with Texas Calibration to design and manufacture the oxygen cargo container. (RTA 2945)

The Master Extractor Industrial Innovations, LLC

Industrial Innovations, LLC, developed the Master Extractor a device that removes telephone poles as easily as pulling toothpicks out of a cake. Before the invention, it took two hours to remove each pole. It now takes 15 minutes. New Mexico State University performed a stress -analysis test that identified the weak points in the Master Extractor, allowing Industrial Innovations to appropriately add more material to strengthen the tool. (RTA 2810)

PORT-A-Field Portable Athletic Field Boundary CS Platinum Sports

CS Platinum Sports developed a portable athletic field boundary system, specifically for field sports, that grew in popularity and is now used in 41 different sports and shipped all over the world. However, because the polyethylene film used to make the boundary tape was custom-sized per sport, the manufacturing process was laborious. CSPS decided that to take the product to the next level, it needed a more automated and efficient process. Rensselaer Polytechnic Institute designed a machine that could handle bigger rolls of tape with the goal of increasing productivity. With the help of SATOP, the system was streamlined and the production process enhanced. (RTA 3888)

BoGo Light LED Flashlight SunNight Solar

SunNight Solar set out to develop a solar-powered flashlight that could be used as the main light source in a home, as well as outside at night for the world ’s poorest regions. The design was not water and shock resistant two critical factors for survival in the harsh conditions in Africa and other developing countries. MEI Technologies evaluated the design and recommended new materials, as well as modifications to the design to make it easier to build. Housing the flashlight in industrial strength plastic solved the durability and water resistance problems. (RTA 2333)

The Big Pitcher—Aeration Technologies, Ltd.

“The Big Pitcher” is a small electric appliance that oxygenates and purifies drinking water. Aeration Technologies, Ltd., needed to overcome two technical issues: the lid did not fit snugly enough and would vibrate and rattle when the device was turned on, and water would fall out when poured. An engineer at United Space Alliance recommended a clear rubber band that would fit around the lip of the lid and prevent vibration and create a snug fit to avert spillage. The cost for the band: 10 cents each. (RTA 2296)

Earmates Ash Manufacturing, Inc.

Ash Manufacturing, Inc., currently makes a disposable windscreen cover that goes over the foam cushion of headsets to mitigate the transmission of germs at call centers. The company wanted to make it easier for the user to place the disposable windscreen cover over the ball cushion. SPACEHAB, Inc., provided a solution by recommending a unique type of plastic, heat sealing the edges, and then running a roller with pins on it to make small perforations in the plastic. SPACEHAB also made referrals for local and domestic manufacturers. (RTA 1227)

E-Z Enema Body Fluid Bag Independent Care Products, Inc.

Independent Care Products, Inc., which manufactures equipment for use by the physically challenged, designed a waste collection bag called the “Body Fluid Bag” for use in administering enemas. The company began work on the design of a waste collection bag but ran into obstacles regarding material selection and operational procedures. The Boeing Company recommended a duck bill valve and suggested a non -abrasive adhesive that bonded the bag to the user without irritation. (RTA 793)

Aerob-A-Jet

O2 Aeration Technologies, LLC

Aerob-A-Jet injects air pockets into water to deliver oxygen to increase the performance of natural aerobic bacteria. SAIC provided an overview of the types of information for a valid scientific study and advised the company on methods for gathering a continuous stream of data that could be downloaded from a remote location. Using SAIC ’s recommendations, Aeration Technologies completed an in-depth scientific study and found that the survival rate was greatly enhanced for the 400,000+ fish per breeding pond exposed to the Aerob -A -Jet technology. (RTA 459)

Flow Barrier Water-Inflatable Dams Flow Barrier

Flow Barrier developed a custom-made portable flood containment device that can be deployed quickly. The tubes in the flood control device fill with water to provide protection. Flow Barrier needed assistance with the configuration of the tubes that form its barriers. Through SATOP, Flow Barrier worked with United Space Alliance, which identified the stress points of the seals inside the tubing and recommended fabricating the outside strips to have slight tension when the tubes are filled. This prompted Flow Barrier to reshape the tubes at certain points to control the flow of water. (RTA 84)

The Ultimate Lock Millennium Lock, Inc.

Millennium Lock Systems developed an innovative security device that can block unwanted access to any door. The company sought technical guidance when it realized the structural design of the locking mechanism didn ’t fit with the marketing strategies. Design by Analysis (DBA) created a three -dimensional model and rendered it with appropriate texture and colors. Studying the product ’s structural mechanism allowed DBA to increase cosmetic appeal by adding a plastic cover. Honeywell Space Systems assisted in fine-tuning the device’s lock mechanism. (RTA 3576)

HydroMax Hydration System HydroMax

HydroMax developed a portable hydration system that allows athletes to drink liquids while on the field. The company wanted to make sure the materials selected were the best and that the design was conducive to its intended use. MEI Technologies examined the materials, researched manufacturers for the bite valve, provided guidance on how to prevent leaks, and recommended see -through tubing for easier cleaning. HydroMAX was then able to identify the proper materials and contact the appropriate manufacturers needed to begin production. (RTA 2149)

Innerloc Cargo Security System Innerloc, Inc.

Innerloc, Inc., developed a cargo security technology that monitors an oceangoing container anywhere in the world. The company needed to identify optimum solar arrays, solar battery bank size, and obtain a discharge analysis to tailor the power load to traveling conditions. Clarkson University researched solar arrays and batteries, made product recommendations, and provided the Innerloc team a formula to show how a selection of solar arrays and batteries would perform based on the environment. They are now able to determine the optimum configuration and customize it to the conditions under which each shipment will travel. (RTA 3320)

LazerRope Docking System LazerRope

LazerRope manufactures a retractable docking line for the boating industry that is usable for personal watercraft to yacht-class vessels. LazerRope approached SATOP and asked for an engineer to review its product to determine if there were ways in which it could be improved. Alliance Partner GB Tech provided design recommendations which LazerRope has incorporated into its watercraft tie-down and dock line storage systems. (RTA 2791)

Potty Patty Potty Training Girl—NPR Innovations

NPR Innovations developed a doll that addressed potty training methods to encourage children during their formative years. The company asked for help finding a commercially available and cost effective valve or switch that would allow the doll to urinate on demand. MEI Technologies worked with NPR on the switch/valve question and offered its expertise on the creation of molds and manufacturing. Through the involvement of SATOP, an innovative doll maker received the engineering help needed to bring the doll to market. (RTA 951)

X-T Fire Fire Extinguisher Mauser Group

The Mauser Group gave the red fire extinguisher a makeover resulting in a sleek silver model. Space Gateway Support (SGS) determined the nozzle insert created an undesirable spray pattern and found an insert that was the correct orifice size. SGS calculated a design for the customization and provided it to the Mauser Group. With the design, Mauser Group proceeded with development and production of the X -T Fire. Alliance Partner MEI Technologies helped improve the fire extinguisher by providing recommendations regarding mounting brackets. (RTA 1912,2234,2316,2514)

CFLO-360 Magnetic Flow Indicator Process Level Technologies, Ltd.

Process Level Technologies, Ltd., devised a magnetically -operated sight flow indicator that addresses the need for an alternative to less reliable armored glass sight flows. The company needed assistance with the turbine design the size, pitch, and overall design of the blades that magnetically spin the flow indicator on the outside . MEI Technologies fashioned the turbine after a standard air foil and provided PLT the required dimensions and specifications. Plans to increase staff size and add equipment and manufacturing space for the production and marketing of the device are currently underway. (RTA 992,1530)

The FlatwareSaver—FlatwareSaver

The FlatwareSaver is a rotating tray system that fits on top of any standard trash container. If anything made of metal or displaying a customized FlatwareSaver sticker makes its way onto the tray, a continuous alarm and LED indicator are set off until the item is removed. The company faced a challenge in finding a reliable metal detector that would easily scan the tray area and several inches into the debris already accumulated in the trash container. Sensis Corporation recommended a method to adapt a metal detector to the lid and helped FlatwareSaver understand the fundamentals of metal detecting enabling the inventor to develop a better product. (RTA 2713)

Thioaptamers AptaMed, Inc.

Master Chops Lip Conditioner Ware Essentials

Ware Essentials developed a new, natural lotion, but the lotion changed consistency in different temperatures becoming either too hard or too runny. The company asked SATOP for a recommendation of an additive to improve the consistency of the product across a reasonable temperature range while not interfering with the product’s basic functionality. United Space Alliance recommended a natural product and unique formulation to address the consistency issues and improve stability. (RTA 1706)

Thioaptamers, a medical treatment for diseases such as cancer, required production by AptaMed, Inc., through a laborious manual method. AptaMed, Inc., needed an automated procedure to reduce production time and asked SATOP for assistance. MEI Technologies automated the process, thereby reducing production time from 7-10 days to roughly one day with an improved quality of the product. AptaMed, Inc., and MEI Technologies subsequently formed a joint-venture company AM Biotechnologies. (RTA 1289, 1531)

The Eradicator Industrial Innovations, LLC

Industrial Innovations, LLC, developed a revolutionary form -removing tool that drastically simplifies the arduous task of removing forms from hardened concrete. The company applied to SATOP for help in reducing the weight of the device to fewer than 40 pounds in order to make it easier to transport and use. Alliance Partner ITT Space Systems Division studied the Eradicator ’s design and recommended using an ultra-light aluminum alloy for parts of the tool, as well as reducing thickness in certain other sections. The recommendations slashed the Eradicator’s weight by 25 percent down to 35 pounds. (RTA 2675)

Traction Jack Traction Jack Company

The Traction Jack is a small, portable device that can be the difference between continuing on your way after sinking into some soft sand or waiting an hour or two for a tow truck that may never arrive. The Traction Jack Company asked SATOP for help in reducing the weight of the Traction Jack. Alliance Partner Design by Analysis recommended several options for materials selection and structural configuration that cut the Traction Jack’s weight in half. (RTA 3351)

SWAT Surveillance Cam TacView, Inc.

TacView is a surveillance camera mounted on a telescopic pole that is used by law enforcement in the field. Officers view the camera images at a safe distance on a hand-held LCD color monitor. TacView decided to give the monitor additional protection by adhering a piece of automobile windshield glass to it. TacView was unsuccessful in permanently adhering the glass to the monitor. United Space Alliance researched adhesives and recommended an adhesive that successfully bonded the windshield glass to the TacView monitor. (RTA 977)

AirCurler AirCurler

The AirCurler is a user-friendly hair-care product that brings the salon-look home. Early prototypes were somewhat successful but did not produce the tight curl desired. AirCurler asked SATOP for help in determining how the shape of the air chamber affects the tightness of the curl. A NASA Johnson Space Center engineer evaluated the design and provided AirCurler with testing parameters on how to find the optimal curl. (RTA 3279)

Hurricane Clips Plylox, Inc.

Plylox, Inc., sells carbon steel window clips used to hold plywood in place to protect windows from damage by hurricanes/high winds or airborne debris. The company approached SATOP for assistance to help figure out how much wind or pressure the residential clips will withstand in order to comply with new applicable state and building codes. NASA Johnson Space Center conducted a series of tests to determine the wind load capacity of the hurricane clips. (RTA 1091)

BellaBreeze Strategic Products Innovation

Strategic Products Innovations (SPI) designed BellaBreeze, an all -in-one patio table, umbrella, heater, mister and fan to provide outdoor relaxation and relief from uncomfortable temperatures. The company’s technical issues involved electronic timed circuitry, product materials, and heat elements. AJT & Associates made recommendations that helped SPI modify BellaBreeze ’s design to make the product more marketable and cost efficient. (RTA 1411)

Fuel Cell Curriculum Development Texas State Technical College

The development of a fuel cell curriculum at Texas State Technical College was guided by an advisory committee comprised of some of the most prominent fuel cell pioneers in the United States, including experts from NASA and the U.S. Army Corps of Engineers. They had an excellent start but needed further assistance to make it an outstanding curriculum. A fuel cell expert from The Boeing Company joined the panel and provided recommendations that led to the development of the final fuel cell curriculum for the college. (RTA 471,895)

Hydrokinetic Turbine—Hydro Green Energy, LLC

Hydro Green Energy, LLC, creates renewable energy technology by placing hydro-turbines in the flow of tidal currents. Hydro Green needed to validate energy output and determine the best model of hydro-turbine. The University of Central Florida completed a study for Hydro Green at its computational fluid dynamics laboratory. Hydro Green was then able to determine which hydro-turbine model would ultimately be manufactured. (RTA 2325)

Vertical Axis Wind Turbine (VAWT) SKYRON Systems, Inc.

SKYRON Systems, Inc., developed a Vertical Axis Wind Turbine (VAWT) that targets a variety of field applications involving onsite generation solutions for both urban and remote sites. SKYRON needed to design a new, cost -effective wind turbine braking and control system to complete development of its VAWT. The Boeing Company conducted braking and control simulations under different wind speeds, evaluated available systems, and recommended an off-the-shelf magnetorheological braking system. This solution allowed SKYRON to complete the design of its Vertical Axis Wind Turbine and head into production. (RTA 3311)

Abnostrain—Revealed Knowledge, Inc.

Revealed Knowledge, Inc., developed Abnostrain, a medical device aiding patients recovering from abdominal surgery. The company decided to seek help with Abnostrain with further evaluation of the product ’s materials. MEI Technologies began by evaluating the material used for Abnostrain and recommended a different material for the rope to prevent slippage, to make sure the material wouldn’t pinch the skin, or damage the blood vessels under the skin. With SATOP’s assistance, Revealed Knowledge, Inc., has had a successful product launch with improved production time and reduced product cost. SATOP also connected the company with manufacturers that are able to meet some of its manufacturing needs. (RTA 1984)

Disposable Stethoscope Diaphragm Entrepreneurs

Thousands of patients die yearly from hospital-acquired infections. Culprits are often germs on stethoscopes. Two entrepreneurs created a device that will keep stethoscopes more sterile, reduce the number of infections, and save lives. Alan Ulert, M.D., and Henry Lang, an engineer, designed a disposable diaphragm for use on stethoscopes that would be replaced each time a doctor treated a new patient. They needed help developing an easy method for the doctors to use the device. Northrop Grumman Technical Services, Inc., (NGTSI) designed and built a prototype of a stationary dispenser to hold the disposable diaphragms. NGTSI ’s prototype allowed the entrepreneurs to finally get their product into production and into use.

Water Leak Detection ADL Robotics, Inc.

ADL Robotics, Inc., designed a water control system to shut off the water supply in 1/100 of a second if a leak is detected. Tests indicated the system was giving false alarms, and the company needed help verifying its test methodology. New Mexico State University (NMSU) evaluated the test methodology and determined it was satisfactory but suggested that the cooling fan was causing moisture ingress, generating the false positives. NMSU recommended installing a capacitor to act as a filter. The addition of the capacitor rendered the system 100 percent accurate for the first time. (RTA 1202)

Air Conditioning Line Guide A-Redemption

An HVAC installer created a safe and efficient means to solve the tedious and difficult task of setting copper refrigerant lines in a tight attic space while installing A/C systems. The Line Guide would enable one person, instead of the usual two, to install the copper refrigerant line while at the same time reducing the potential for damage to the lines from impediments. Early prototypes encountered friction when pulling the line set through the guide. AJT & Associates recommended a two -piece opening in the metal guide that would allow the user to adjust the opening to the needed width and still keep the wall stud structurally firm. The adjustment works without damaging the copper lines and insulation. (RTA 936)

Propane Tank Recycling Tri-State Scrap Metal

When the EPA mandated new, safer valves for barbecue grill propane tanks, owners could no longer refill older tanks, and there was no way to legally dispose of the containers because of the hazardous residue left inside. Tri -State Scrap Metal sought to develop a tool or methodology to “diffuse” the dangers in handling the tanks. The Boeing Company assisted by designing a brass elbow that is welded over the top tank opening. This allows air to be blasted to the bottom of the tank, and the propane squirts back through the elbow and out the hole. The result is no fumes, and it is safe to operate. Since word of this new device has gotten out, several other recyclers have asked for information on the process. (RTA 1745)

Air Motor Safety Silencer PSI Automation

Air motors are critical for many manufacturing operations, but they generate a workplace hazard of noise that can exceed 115 decibels. PSI Automation designed and installed a muffler to reduce noise but still encountered excessive noise. Using a high-tech sound analyzer and microphones, Johnson Engineering assisted PSI by assessing the noise generated by the air motors, determined that the motor blades were generating much of the noise, and recommended design changes to the blades. Additional tests showed PSI was on the right track with its new safety silencer.

Oil Well Corrosion Protection Aliron Tool Research

Corrosion is a huge problem in the oil industry for downhole oil well components. Aliron Tool Research sought to create a new corrosion -resistant coating but realized it needed metallurgical analyses conducted on the coating to validate its corrosion resistance performance. New Mexico Institute of Mining and Technology (NMIMT) was provided with samples of downhole tools that had been coated with Aliron’s process and then tested in wells in Texas. The metallurgical and corrosion testing performed by NMIMT substantiated the effectiveness of the coating. The company is moving forward with development of Aliron Coating and is preparing the product for commercial use. (RTA 1539)