Lightweight Recuperator for Electrified Aircraft Propulsion

Electrified Aircraft Propulsion (EAP) is a growing NASA technology effort that could enable new configurations of aircraft. With the potential to transform the transportation and services markets, vehicle classes of interest include single-aisle, thin/short haul, and urban air mobility. These vehicle concepts rely on hybrid electric systems to provide propulsive power through the use of a turbo-generator combined with electrical energy storage. For turbo-generators/range-extenders utilized in regional EAP concepts, small lightweight turboshaft engines are an excellent choice due to their maturity and availability. However, at small power scales, gas turbines are less efficient. This can be addressed by using a recuperator to inject waste heat from the turbine back into the thermodynamic cycle upstream of the combustor. Micro Cooling Concepts (MC2) has developed technologies for fabricating extremely compact metallic heat exchangers with high heat transfer while reducing size by 3-5X and weight by 2-3X, using the printed circuit heat exchanger (PCHX) approach.Using additive manufacturing to create heat exchangers with finer scale and higher aspect ratio features can magnify the advantages of MC2’s existing technology, resulting in affordable recuperators with minimal weight, volume, and pressure losses. Analysis shows that the PCHX approach gives ~50% weight reduction, while the 3D Printed/Hybrid recuperators provide an additional 20% weight reduction. These weight reductions translate directly into shorter fuel payback times and opportunities to increase payload or range. The program will begin with requirements definition and design studies to size the heat exchanger and assess flow distribution. 3D printing studies will assess manufacturability of the concept, followed by fabrication and testing of proof pressure test specimens, representative of a full-scale recuperator design. The program will conclude with a design update to prepare for the Phase II effort.

Technology applicable to any NASA program where heat exchangers are required and weight has a significant impact on system performance. Examples include: Ultra-Efficient Commercial Vehicles Transition to Low-Carbon Propulsion Advanced Air Transportation Technology (AATT) Project Revolutionary Vertical Lift Technology (RVLT) Convergent Aeronautics Solutions (CAS) Project ASCENDS (Active Sensing of CO2 Emission Nights, Days, Seasons) DRM 5/6/7/8/9 (Asteroid Redirect, Crewed to Asteroid/Moon/Mars)

Lightweight compact heat exchangers have uses across wide range of applications. Impact cannot be overstated as applicability to military and commercial sectors is vast. Energy / Transportation / Space

This is early/mid-stage (TRL 3) — the most realistic path in is NASA SBIR/STTR, which funds small businesses and research institutions to develop technology aligned with NASA's needs (equity-free, phased funding). Check whether a current SBIR/STTR solicitation topic overlaps with this project's technology area, or contact the project directly (above) to ask.

None of these are guaranteed paths for this specific project — TechPort itself doesn't have an "apply" button. Reaching out to the contact(s) above with a specific question is usually the fastest way to find out what's actually open.