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Completed TRL 4 (started at 2, targeting 4)
Initially, the team will explore various felting vendors capable of fabricating a blended carbon/phenolic felt. In parallel, early felting trials at partner (AFFCO) will be conducted using their benchtop R&D felting machine. Two “builds” are currently planned under this effort. The first build will fabricate felts at a range of carbon to phenolic ratios and constant felt density (0.2 g/cc). Each felt will be evaluated on key performance metrics including manufacturability, thermal conductivity, mechanical robustness, and char yield. Once suitable carbon/phenolic fiber ratio is determined, the second build will focus on felt density optimization in the range of 0.12 to 0.3 g/cc while maintaining a constant carbon/phenolic ratio. Physical, mechanical, and thermal properties of the felts will then be characterized prior to finalizing the baseline “PICA-Flex” material processes
NASA has few high TRL thermal protection (TPS) today to support future missions. These materials take a long time to process such as month long infusion steps that need complex equipment and infrastructure and yield toxic byproducts. While also requiring complex integration techniques. Emerging commercial space requires low-cost, low-density, rapidly producible material with low env. footprint and a TPS that is easily integrated. Process simplifications and cost savings are also strategic for future NASA missions inc. Mars & small planetary bodies.
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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.
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