3D Print Small Flight Heat Shield Prototype, Year 3

The goal of this project is to automate the processes for making and installing ablative TPS on large entry vehicles in order to significantly reduce the cost of TPS for future flight vehicles. New TPS materials and compatible 3D printing techniques are being developed and tested. Once successful the design space for heat shields will be less constrained by the manufacturing methods and the automated processes will reduce costs and improve quality. For this upcoming year, the capability to 3D print a heat shield for a small capsule will be demonstrated. Furthermore, flight opportunities for future flight tests will be investigated and the efforts to prepare a STMD proposal will be initiated.

Technology Gap Being Addressed This project supports the NASA Technology Road Maps of Entry, Descent and Landing (TA09), Materials, Structures, Mechanical Systems and Manufacturing (TA12) and Thermal Protection System (TPS) (TA14) technology gaps. Future spacecraft, such as lunar-return vehicles, need robust, mass efficient and low cost TPS. Part count and seams between TPS components need to be reduced. Automated manufacturing and installation of TPS provides potential solutions to these technology gaps. Build a 3D-printed prototype heat shield for a flight opportunity to demonstrate the extremely low cost and unique capability of 3D printing heat shields for Lunar-return or Mars-entry vehicles in collaboration with NASA Ames, ORNL and four STTR small business/university teams. This project supports the NASA Technology Road Maps of Entry, Descent and Landing (TA09), Materials, Structures, Mechanical Systems and Manufacturing (TA12) and Thermal Protection System (TPS) (TA14) technology gaps. Future spacecraft, such as lunar-return vehicles, need robust, mass efficient and low cost TPS. Part count and seams between TPS components need to be reduced. Automated manufacturing and installation of TPS provides potential solutions to these technology gaps.

This is early/mid-stage (TRL 4) — 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.