Dynovas Advanced Pressure Resin Transfer Molding (DAP-RTM) for Large Three Dimensional Woven Preforms

NASA is progressing the development of thermal protection system (TPS) concepts using Large 3D-woven preform composites to facilitate both robotic and human space missions, particularly during entry and aerocapture phases. These advancements find application in missions to celestial bodies such as Mars, Venus, and Titan, as well as in suborbital missions and those returning to Earth. The woven preforms that serve as constituents for these new materials tend to have a high fiber density, large volume, and intricate weave patterns. These attributes have consistently shown that traditional resin transfer molding processes such as vacuum assisted resin transfer molding (VARTM) and vacuum resin film infusion (RFI) are incapable of achieving full densification (<2% void volume). The Dynovas Advanced Pressure Resin Transfer Molding (DAP-RTM) system specifically addresses NASA’s call for development of an improved and more reliable method to infuse NASA’s 3D Multifunctional Ablative TPS (3D-MAT) and other large three dimensional preforms. The DAP-RTM system provides a novel solution that leverages the extensive experience of the Dynovas staff in this technology area. The proposed development work plan will advance current state of the art, reduce schedule, increase yield, and reduce cost for Large Three Dimensional Woven Preforms Composites through implementation of three key process improvements: 1. Improved Resin Flow 2. Advanced Preform Preprocessing 3. Tailored Mechanical Injection

The 3D-MAT material system is already qualified for human spaceflight on the Orion mission and multiple NASA centers are exploring the use of other Large Three Dimensional Woven Preform Composites for supporting high temperature entry vehicles. Moon exploration, Mars surface missions, Venus, and gas giant exploration are specifically called out in NASA plans. The key TRL milestones of the DAP-RTM clearly align with critical NASA technology milestones for human exploration and operations. Non-NASA markets for Large Three Dimensional Woven Preform Composites are primarily made up of commercial spacecraft OEMs, such as SpaceX, Sierra Nevada Corporation, Astrobotic, Blue Origin, Ceres Robotics, Deep Space Systems, Draper, Firefly Aerospace, Intuitive Machines, Masten Space Systems, Moon Express, Orbit Beyond, Tyvak Nano-Satellite Systems, and Lockheed Martin. Through the Commercial Lunar Payload Services program, most lunar shipments will be NASA contracted (e.g., in the construction of the Gateway), but driven by the commercial industry. Therefore, while NASA will indirectly benefit from the deployment of the DAP-RTM the next generation of spacecraft and lunar landers to Dynovas will be non-NASA based. Other space-based markets may include operation on spacecraft for orbiting debris removal, experimentation satellites, etc. Non-space-based markets could include remotely industries that require high compression strength and high operating temperatures, such as the oil and gas industry. As the DAP-RTM is matured, Dynovas will continue to review potential non-NASA markets to maximize NASA’s investment and Dynovas’ return on the SBIR program.

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