Additively Manufactured TPS Arc Jet Evaluation (MTPS-ACO)

Cornerstone Research Group, Inc. (CRG) in collaboration with NASA Johnson Space Center (JSC) and NASA Ames Research Center (ARC) proposes to conduct a series of arc jet tests to assess the performance of new materials and manufacturing processes for use in TPS applications. CRG, along with proposed partners, Tethers Unlimited, NanoSonic, and Intelligent Optical Systems, Inc. (IOS) have been developing new materials and processes to automate the production of heat shields and TPS through on-going SBIR/STTR efforts. All teaming partners are currently completing an FY19 NASA STTR Phase I contract awarded under Focus Area 14 InSpace and Advanced Manufacturing, Topic T12.05 In-Situ Curing of Thermoset Resin Mixtures and this effort will build from the results of each contract by advancing the TRL of multiple technologies simultaneously, giving NASA valuable data in support of future missions. The proposed Announcement of Collaboration (ACO), supported through an Unfunded Space Act Agreement, will be between NASA and CRG. CRG will act as the primary Partner and will coordinate activities with NASA and within the proposed team (Tethers Unlimited, NanoSonic, and IOS), to ensure success of this effort. The program will consist of two (2) test events at the Ames Arc Jet Complex. CRG and the proposed team will work with NASA to identify specific test conditions and measurements for each test event. Notionally, the first test event will serve as an exploratory activity to assess how well baseline materials perform under representative conditions. The team will take lessons learned from this first round of testing to refine materials and processes and optimize for the second test event. The test articles for both test events will be additively manufactured with an iso-Q front surface geometry, roughly 4” in diameter and approximately 1” in thickness. CRG and the proposed partners will provide all physical test articles to NASA. JSC and ARC will provide test planning and execution support, including test facilities under this arrangement.

The ability to 3D Print TPS onto an aeroshell will reduce part count and will combine TPS fabrication with TPS integration thereby simplifying the number of processes. Pricise robotic placement of engineered TPS material has the potential to create materials with minimal flaws and with a repeatable structure not possible with human fabricated systems. Integration directly on a substrate has the potential to reduce cost and would likely be of interest for commercial space because this automated installation approach removes some of the complexities heritage systems require. i.e. tile installation on Strain Isolation is a complicated process.

This is early/mid-stage (TRL 5) — 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.

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