Affordable Resins for High-Performance, Ablative Thermal Protection Systems

Cornerstone Research Group Inc. (CRG) proposes to advance fundamental material development of a high-temperature resistant, multifunctional polymer system conceived and demonstrated previously by CRG, which will provide NASA with an innovative, low-cost material for thermal protection systems. The proposed material technology results in a polymer system that transitions from a thermoplastic at temperatures below 230F, to a thermoset at temperatures above 230F, and finally to a graphite-like material at higher temperatures. CRG has demonstrated the concept and feasibility of this material, trademarked as Metagraphite, during a previous research effort. In that effort, CRG confirmed that bulk thermo-mechanical, thermal, and electrical properties of the polymer could be altered through the application of varying amounts of heat. The described polymer can be combined with fabric reinforcement to create a system that presents NASA with the potential for low-cost, adaptive structural materials with properties ranging from those of thermoplastics to carbon matrix composites. Such materials would find wide use in thermal protection systems and high-temperature components for launch propulsion system rocket nozzles. The extremely low-cost raw materials and the range of material properties available will enable innovative processing methods and reduced component manufacturing costs when compared with state-of-the-art materials.

Supporting NASA's Ames Research Center, this project's technologies directly address requirements for low-cost, thermal protection materials and manufacturing techniques. This project's technologies offer dramatically reduced material cost with appreciable thermal stability and environmental durability. These properties make Metagraphite a promising material for thermal protection systems and insulators especially in applications where the high strength-to-weight ratio of a polymer is desired. CRG's Metagraphite material has broad applicability for NASA in launch vehicles, aircraft and spacecraft applications where thermal stability, processability, low weight and cost are of concern.

This technology's attributes for launch vehicle propulsion system nozzle components should yield a high potential for private sector commercialization for the following areas: -Performance brake pads for high-end automotive manufacturers such as Bentley, Bugatti, Ferrari, Lamborghini, and Porsche. Carbon matrix composites are already used in this high-temperature, high-abrasion application. Metagraphite would offer an affordable alternative to currently used materials -Racing and performance automotive engine components where thermal stability and light weight are absolute necessities. Formula 1 racing, where CRG has performed in past commercial programs, may have significant potential from an R&D perspective -CRG's partners, may aid in transition of this technology into the rail industry for flame-resistant insulation. -Nozzle components and insulators for Commercial Access to Space propulsion systems, such as the rocket engines powering SpaceX Falcon and Virgin Galactic SpaceShipTwo vehicles.

This is early/mid-stage (TRL 3) — 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.