Development of Low-Cost High Temperature Reusable Thermal Protection System (LCHT TPS - ACO)

Sierra Space is developing a low-cost, high-temperature, reusable Thermal Protection System (TPS) for application on the Dream Chaser® Space Plane. Shape stable and reusable TPS is a key enabling technology for the Dream Chaser® Space Plane and the space transportation industry as a whole. The proposed TPS materials will be developed by Sierra Space, in collaboration with Oak Ridge National Laboratory’s (ORNL) Manufacturing Demonstration Facility (MDF). The new TPS will be comprised of a ceramic insulating base and a high-temperature, oxidation resistant outer layer, creating a TPS tile that is capable of multiple flights at surface temperatures up to 3,100 °F. Currently, most reusable TPS are limited to temperatures below 3,000°F. Through the use of advanced manufacturing techniques, the new TPS manufacturing costs will be reduced and the production rates will be increased. Sierra Space and Oak Ridge National Laboratory will produce test articles of multiple material types for screening at Sierra Space's Aerothermal TPS Screening Facility. Material property testing will be conducted by Sierra Space and NASA JSC. Oxidation resistance will be verified during testing in a plasma torch facility at the University of Texas at Austin. In order to qualify the new TPS for flight, and eventual flight on a crewed space plane, arc jet testing will be conducted at NASA Ames Research Center and radiant heat testing will be conducted at NASA JSC. This material development and qualification effort will result in a new reusable TPS with a higher temperature capability and with a significant reduction in per unit manufacturing and life-cycle costs.

The development of a new TPS with a higher temperature capability for multiple flights will reduce the need to replace/refurbish the TPS on the Dream Chaser® space plane between flights, which significantly reduces the costs of each space flight and reduces the time to prepare the vehicle for the next flight. Furthermore, the use of advanced manufacturing techniques to create a shape-stable, reusable TPS will be used to lower manufacturing costs and increase the production rate for the new TPS. The new manufacturing capabilities which are being developed in collaboration with Oak Ridge National Lab will be setup in a pilot production facility at Sierra Space in Louisville, CO. A new Sierra Space TPS production facility is being setup in Florida to be closer to the planned Dream Chaser® launch and landing operations. This project will result in a new higher-performing and lower cost TPS that will be qualified for space flight.

This is a mature technology (TRL 7+) — the realistic path in is usually NASA's Technology Transfer Program: licensing an existing NASA patent, or a Space Act Agreement to use NASA facilities/expertise directly. NASA also runs a startup licensing program with no upfront fee for companies formed to commercialize a specific NASA technology.

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.