3D Reinforced Composites for Improved Impact Resistance in Spacesuits

This proposal seeks to develop an advanced material solution for the hard upper torso (HUT) component with improvements in impact resistance. The current HUT is a 2D laminate which is more susceptible to delamination between plies under impact conditions. Materials Research & Design is proposing an investigation of 3D braided/woven composites for improved impact strength. The overall objective of this Phase I program is to demonstrate the ability to improve interlaminar shear strength of an S-2 / epoxy composite material with across-ply reinforcement to improve impact resistance. Phase I will focus on the fabrication and characterization of at least one material system consisting of 3D woven S-2 fibers with an epoxy matrix. Characterization of this material will consist of flexure testing and asymmetric four-point bend testing to derive in-plane tensile modulus and strength and interlaminar shear strength. These measured material properties will be used to develop a material model to estimate properties for other woven/braided architectures. These additional material systems, along with the fabricated material will be simulated in finite element models, simulating the performance under impact loading. Results from these cases will be compared for all material architectures to determine which has the greatest potential to survive operational impact scenarios. The architectures evaluated will be ranked by their potential for further evaluation in Phase II. The values for comparison include estimated/measured strengths, mass savings compared to the baseline material, and estimated performance based on the impact loading finite element analysis. Phase II of the program will focus on the maturation of the candidate materials down-selected from the Phase I results. It will include additional testing of candidate materials, specifically impact and permeability testing. Phase II will conclude with a full or sub-scale prototype fabricated of the final material.

NASA has set its goals toward human exploration of the Moon and Mars, requiring the development of advanced spacesuits for operability in adverse environments. NASA's mission directives are best summarized by the goals of their Moon to Mars (M2M) program. The objective of this program is to further develop and demonstrate capabilities that will not just allow humans to explore the Moon and Mars, but thrive and continue to grow there. Specifically, one objective is to enable EVA operations on Mars, using lunar surface opportunities for demonstration as appropriate, to facilitate risk mitigation for sustained lunar missions, and increase life robustness for long duration lunar missions. The NASA pressure garment system (PGS) roadmap specifically highlights a need for additional structural protection, durability, and mass reduction for Mars-enabling technologies. 3D woven composites are a great solution to improve impact resistance compared to the current composite hard upper torso design, while maintaining the decreased mass benefits of a composite material. In addition to the spacesuit applications, 3D reinforced composites have numerous other potential applications that NASA can explore, especially in the realm of hypersonics. These applications include any material that can benefit from an increase in interlaminar strength, which would be a requirement for materials undergoing high thermal shock, impact loading, some other form of mechanical through-thickness tensile loading. Specific examples of these applications include ablators for blunt bodies, heat shields, airframe components, and antenna windows. The global spacesuits market size was valued at 123.7 million USD in 2021, and is projected to grow to 1,576.3 million USD by 2030. Private players such as SpaceX, Boeing, Blue Origin, Virgin Galactic, and Axiom Space have all announced the future opportunity to provide space tourism, which leads to a rising demand for advanced, lightweight suits that are not only operable by trained astronauts but must also be operable by a common civilian. Composites offer low weight for efficiency but require special attention to be suitable for these uses. Furthermore, composites in general are weak when struck through the thickness, that is, impact damage. Technology developed in this effort has the potential to improve composite performance, specifically impact resistance. In addition to spacesuit development, 3D reinforced composites also have other applications in the aerospace industry, including ablators for blunt bodies, heat shields, airframe components, and antenna windows. The commercialization strategy for this program will be multifaceted. The early stages will involve numerous discussions with NASA personnel to identify candidate programs that will benefit from lightweight, 3D-woven composites. Additionally, MR&D will leverage existing relationships and knowledge of numerous ongoing programs to identify other spacesuit or vehicle applications which could also benefit from this technology. These contacts include engineers and managers at Collins Aerospace, Aerojet Rocketdyne, Northrop Grumman, Lockheed Martin, and Boeing. MR&D has a long history working on a variety of materials development programs with each organization. While some of these companies may be seen as competitors in the development of vehicle or spacesuit components, a potential collaboration will help MR&D more quickly expand its own marketing ability.

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.