Design, integration, documentation, and training on Class IV laser safety interlocks

STATEMENT OF WORK ISAAC Laser Barrier Safety Interlock System Installation 1.0 Introduction/Background: The Integrated Structural Assembly of Advanced Composites (ISAAC) facility supports a variety of composites manufacturing activities, including Automated Fiber Placement (AFP) for aeronautical and space research support. In 2025, the AFP end effector was upgraded to include a laser heating system, enabling the ISAAC facility to make use of thermoplastic materials and expanding the scope of research supported by the facility. In order to safely operate the Class IV laser associated with this upgrade, a light-safe laser barrier and interlock system rendering the area around the ISAAC enclosure a Class I laser operation area is required. This statement of work describes the work associated with the laser safety interlocks for the barrier and interlock system. 2.0 Scope of Work: The work described by this statement of work includes the integration, design, and documentation of the laser safety system for the ISAAC AFP end effector, part of the ElectroImpact-built ISAAC robotic system in the ISAAC facility. This work necessarily also includes acceptance testing, baseline testing, and training for the Variable Spot Size Laser (VSSL), as installed on the AFP end effector, and laser safety system. 3.0 Objectives: The installation and integration of laser safety interlocks will allow for the safe operation of the Class IV laser installed on the ISAAC AFP end effector as part of the development of thermoplastic materials development capability for the ISAAC facility. 4.0 Description of the Work/Contractor Tasks: 4.1 Integration, design, and documentation of the laser safety system for the laser capable ISAAC AFP end effector Contractor will work closely with NASA Langley personnel associated with ISAAC and contractor and subcontractor associated with the construction of the laser safety barrier (CMOE Construction Task CTN 5172) to ensure appropriate design, integration, and documentation of laser safety interlocks, including physical, electronic, or software interlocks, which will interrupt operation of the ISAAC robot and AFP laser heating system if triggered. Interlocks are to turn off the laser heater and render the laser heater inoperative until reset by an operator. 4.2 Baseline and acceptance testing Contractor shall perform baseline and acceptance testing of laser AFP heating system, including material laydown and tuning, testing of all safety interlocks, and testing of all potentially impacted systems prior to completion of contract. 4.3 Training Contractor shall provide onsite training for NASA Langley personnel associated with the ISAAC facility as end users of the laser heater system. Training shall include, but may not be limited to: operation of the AFP end effector with laser installed, operation of safety interlocks, appropriate stowage of laser system when not in use, -- 1 of 2 -- appropriate methods of unstowing and preparing laser heating system, appropriate methods of AFP manufacture using the installed laser heating system. 5.0 Deliverables: 5.1 Contractor shall provide NASA with appropriate drawings and documentation of installed and integrated laser safety interlocks at the conclusion of installation and integration. 5.2 Contractor shall provide NASA with any operation manuals associated with the AFP laser heater. 5.3 Contractor shall provide NASA with any training materials, such as example programming or reference documents, associated with completion of operator training for the AFP laser heater, other than those named in the Government-furnished property section of this document. Other Considerations: 1.0 Applicable Documents/Background: 1.1 Incorporation of Design Package Documents The Design Packages developed under CMOE Design Task (CTN 4340) and CMOE Construction Task (CTN 5172) are incorporated into this SOW by reference. 2.0 Government-furnished property: NASA Langley will make available thermoplastic AFP material and any required suitable consumables to enable baseline and acceptance testing (ex. Thermoplastic tow preg material and consumable teflon substrate) 3.0 Period of Performance: Period of performance shall be informed by coordination with the contractor performing the CMOE Construction Task (CTN 5172) of the laser barrier. Period of Performance is currently estimated by the CMOE Construction Task proposed schedule to begin in January 2027 and end in March 2027, but is subject to change. NASA will inform contractor of any changes to expected schedule when these changes become known to NASA. -- 2 of 2 --