Radiation and H2 Durable Nuclear Thermal Propulsion Fuel Element Insulator

NASA’s Marshall Space Flight Center (MSFC) has identified a need for new higher-temperature fuel element insulators for fission-based, liquid hydrogen (H2) fueled, Nuclear Thermal Propulsion (NTP) engines. NanoSonic is a small, advanced materials company currently supporting two NASA CubeSat flights in 2025 with our radiation shields as well as the LGM-30G Minuteman III Intercontinental Ballistic Missile (ICBM) with parts that must survive extremely harsh environments. While NTP reactors offer a specific impulse of ~ 900 seconds, more than twice that for state-of-the-art chemical rocket engines such as the Saturn V, weight reductions are still needed. Space nuclear propulsion (SNP) and doubled fuel efficiency may cut current transit time to Mars of 6-months by half, as well as astronauts’ exposure to galactic cosmic radiation (GCR) and supplies needed. Current insulators are based on combinations of SiC, ZrC, and graphite materials. For this SBIR, a new low thermal conductivity nanoporous ceramic insulator is offered based on SiC and ZrC MXenes layered with HfC and TaC to increase thermal stability up to ~4,000 ºC. This design shall minimize heat transfer between the high temperature fuel elements of 2727 ºC and lower temperature moderator material of 527 ºC to enable further mass reductions and higher-temperature gas-reactor performance for future small NTP reactors.

The objective of the proposed NASA Phase I SBIR program is to design and produce an extremely high temperature fuel element insulator for future Nuclear Thermal Propulsion engines. Here, NanoSonic shall develop high pressure H2 and radiation durable, low thermal conductivity, fuel element insulators for NTP reactors and engines to support manned missions to Mars and deep space. The insulators shall initially be developed for NTP and SNP applications. Fuel element insulators exist for prior Project Rover and Nuclear Engine for Rocket Vehicle Application (NERVA) programs, however, current NTP performance requires higher core temperatures to further reduce NTP engines. Faster and more robust space nuclear propulsion (SNP) driven manned missions to Mars and deep space will reduce radiation exposure to astronauts. This technology will also support the planned NASA and DARPA NTP demonstration flight planned for 2027. The insulators shall initially be developed for NTP and SNP applications and later for related aerospace and hypersonic systems. The shielding and H2 durable aspects of these materials shall also be explored in widespread electronics, H2 dispensing systems, cryogenic H2 storage, medical systems, and commercial space. NanoSonic has conducted a comprehensive patent review and ensures that there is no existing patent or perceived patent infringement based on the proposed innovation.

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.