Low-Cost Manufacturing of Reusable Thermal Protection Systems (TPS) (TPS)

Commercial space needs lower cost and robust thermal protection system (TPS) solutions for current and next-generation reusable transportation vehicles to support the formation of a sustainable low-Earth orbit (LEO) economy. The current state of the art for reusable TPS is largely derived from Space Shuttle heritage; however, these are constrained by high costs, long lead times, supply chain challenges, and performance limitations. There is a need for new solutions for reusable TPS suitable for return from LEO with reduced costs and feasible, scalable paths for manufacturing and integration. A cohesive and effective TPS solution should be considered for the underlying bulk materials, manufacturing processes, integration and attachment methods, and the long-term operational requirements of a vehicle equipped with such a system. The long-term objective of this proposed work is to leverage novel polymer-derived ceramics (PDCs) materials development and existing larger-format Additive Manufacturing (AM) processes to develop and implement processes, optimized materials, and integration design strategies, that can ultimately be used quickly and cost effectively to manufacture optimized reusable TPS solutions. The Phase I effort will focus on: 1) working with stakeholders to define key metrics and guide development, 2) formulating application specific PDC precursors for compatibility with large format AM processes, and 3) demonstrating technical feasibility through prototyping and materials property testing If successful, Sporian will be well positioned for Phase II efforts focused on producing full demonstration units for stakeholder testing, addressing vehicle integration, and meeting benchmarks required for technology transition and commercialization. Work will be done through a collaboration between Sporian Microsystems and the National Institute for Aviation Research (NIAR).

All missions that return to Earth or enter a planetary atmosphere require TPS to protect the spacecraft from the high heating associated with hypersonic flight. TPS with increased temperature capability and improved reusability will benefit the development and operation of spacecraft, whether used for return of humans or cargo to Earth from LEO, return from the Moon, or landing on Mars. The technology would have utility across the agency, including the Exploration Systems Development Mission Directorate (ESDMD), Space Operations Mission Directorate (SOMD), Commercial Crew Program, and Commercial LEO Destinations Program. The science and technology generated also would benefit the Science Mission Directorate (SMD) and Space Technology Mission Directorate (STMD). The potential markets for a lightweight, compact, high temperature, corrosion-resistant refractory materials is substantial. Similar to NASA applications, this technology can be used for DOD hypersonic vehicles, missiles, and rockets and other stand-off applications. Outside of aerospace, other markets includes refractories, nuclear reactors, fossil fuels, unmanned aircraft, energy generation, and any other application that would benefit from low-cost prototyping and production of similar ceramic components.

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.

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