Moldable and Curable Silicon Carbide Prepreg For Hypersonic Thermal Protection Systems

The purpose of sub-topic T12.05 is to demonstrate the ability to significantly improve the manufacturing processes of Thermal Protection Systems (TPS) used in human-rated spacecraft with the intention to reduce cost and improve system performance. New TPS materials and compatible additive manufacturing processes which allow deposition, curing, and bonding over large spacecraft areas are required for future NASA Human Exploration and Operations Mission Directorate (HEOMD) Lunar and Mars missions, and Science Mission Directorate (SMD) planetary missions which require hypersonic entry through an atmosphere. During Phase 1 Goodman Technologies (GT) completed the following: TPS Composite Formulation (based on requirements/material properties/rule of mixtures), including thermal protection system (TPS) layer and full composite schedule (build layer & direction definition). Mechanical Design/Analysis of the AM (Additive Manufacturing) TPS. Formulated Nanoresins/Nanopastes suitable for both TPS ablative layers and reusable hot structure/aeroshell, interlaminar matrix bonding compounds for tapes and prepregs (prepregging nanopaste), and adhesive nanopastes. Designed processes and defined equipment for large-scale, automated manufacture of CFCNC’s, and demonstrated the individual steps sequentially. For Phase II, GT in partnership with the Hawaiian Nanotechnology Laboratory (HNL) at the University of Hawaii at Mānoa, (UHM, is a Minority Serving Institution) propose an Automated Robotic Manufacturing System (ARMS) capable of Additively Manufacturing (AM) purposefully engineered monolithic CFCNC TPS and Reusable Hot Structures. Our Silicon Carbide (SiC) based 3D printable and moldable nanopastes together with SiC (Hi-Nicalon) reinforced prepreg for the molding, curing and joining of Continuous Fiber Ceramic Nano-Composites (CFCNCs) overcomes the issues of delamination and segment separation and will have tremendous payoff for spacecraft TPS and hypersonics in general.

NASA New Frontier missions and in situ robotic science missions require heat shields and thermal protection systems for Venus probes and landers, Saturn and Uranus probes, and high-speed sample return missions from Comets and Asteroids. The Human Exploration and Operations Mission Directorate (HEOMD) is, of course, spearheading the efforts to expand a permanent human presence beyond low-Earth orbit, i.e., to the Moon and to Mars. Many large surface area TPS for spacecraft are needed.

Non-NASA applications of low cost, rapidly manufactured CFCNC TPS are Commercial Space Programs and Programs of Record for the Department of Defense. GT’s technology provides t a retrofit opportunity for missiles, missile fairings, aeroshells and other strategic air platforms and cruise missiles. The large Automated Robotic Manufacturing System will be portable to System Primes and OEMs.

This is early/mid-stage (TRL 6) — 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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