An integrated multi-physics and multiscale modeling framework for simulating infusion and curing of Thermal Protection System (TPS) materials (TPS)

This proposal introduces an integrated simulation framework designed to optimize the manufacturing of advanced thermal protection systems used in aerospace applications. The framework employs a multi-physics, multi-scale modeling approach that captures both the macro-level resin infusion and the micro-scale curing processes. It integrates commercial CFD (STAR-CCM+) and FEA (Abaqus) third party tools with AnalySwift’s proprietary micromechanics code, SwiftComp, to simulate complex phenomena such as variable porosity within 3D woven preforms, resin off-gassing, curing-induced shrinkage, and chemical kinetics. Funding will support the development of physics-based models, the creation of user-friendly software plugins, and experimental validation to ensure the accuracy of predicted infusion quality and structural performance. By reducing reliance on trial-and-error methods and streamlining process optimization, the resulting toolkit will lower production costs and accelerate design cycles for high-performance heat shield components. Target markets include both aerospace sectors and high-performance composite manufacturing industries, where precise process control is critical to ensuring reliability under extreme conditions.

The proposed simulation framework directly supports NASA mission directives by addressing the manufacturing challenges associated with Thermal Protection Systems (TPS) essential for safe spacecraft entry, descent, and landing. Through accurate modeling of resin infusion and curing processes, the toolkit predicts void formation and defects, ensuring optimal heat shield performance under extreme thermal and mechanical loads. By integrating multi-scale analyses—from the microstructural behavior of 3D woven preforms to macro-scale fluid dynamics—the technology enables rapid design optimization and quality assurance of TPS materials. This enhanced simulation capability will help NASA reduce development risks, minimize costly prototyping cycles, and improve the reliability of TPS components for both robotic and human space missions. Furthermore, the framework’s adaptability makes it a valuable tool for designing reusable launch vehicle components and other mission-specific thermal protection solutions. Beyond its immediate NASA relevance, the integrated simulation framework offers broad commercialization potential in industries reliant on advanced composite manufacturing. The toolkit’s ability to accurately predict resin infusion behavior and curing responses can transform manufacturing processes in aerospace, defense, automotive, and other sectors where high-performance composite materials are essential. By reducing the need for extensive experimental trials and enabling precise control over composite quality, the technology can lead to significant cost savings and shorter product development cycles. Its user-friendly interface and compatibility with widely used CFD and FEA software ensure seamless integration into existing industrial workflows. Strategic licensing and partnership opportunities further enhance its market appeal, making it an attractive solution for companies seeking to innovate in the design and production of lightweight, high-strength components for commercial satellites, deployable structures, and next-generation transportation systems.

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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