Lattice-based Thermal Mitigation Skin Material for High-Altitude Sounding Rockets

This proposal introduces a lattice-based thermal mitigation skin designed to enhance thermal protection while reducing mass for high-altitude sounding rockets and reentry vehicles. The innovation consists of a pure alumina (Al₂O₃) lattice covered with a fused silica-phenolic composite ablative coating, combining high-temperature resistance, mechanical strength, and superior heat dissipation. The alumina lattice provides structural support and thermal stability, while the ablative silica-phenolic layer minimizes heat penetration through controlled charring and insulation. The resin film infusion (RFI) method ensures efficient, scalable manufacturing without autoclave curing, reducing production costs. To validate thermal and mechanical performance, Density Functional Theory (DFT) simulations will optimize lattice porosity, composite formulation, and infusion techniques. Aerothermal simulations (leveraging SpaceWorks' QuickShot™) will model the material’s behavior under reentry conditions, while a desktop-scale prototype will undergo thermal and mechanical testing to compare experimental data with computational predictions. This innovation directly supports NASA’s Sounding Rocket Program (NSRP) by offering a lightweight, high-performance alternative to traditional TPS materials like PICA and Avcoat. Key advantages include lower areal density, enhanced insulation (thermal conductivity ~0.05 W/m·K), and streamlined manufacturing, positioning it for suborbital reentry and hypersonic applications. Phase I will establish feasibility, paving the way for Phase II suborbital flight tests and collaborations with NASA and commercial aerospace partners.

The proposed lattice-based thermal mitigation skin enhances thermal protection, payload survivability, and reusability for NASA’s Sounding Rocket Program (NSRP). By reducing TPS mass while improving heat resistance, this innovation supports suborbital payload recovery, high-speed reentry, and cost-effective flight operations. The alumina lattice structure with a fused silica-phenolic ablative coating provides superior thermal shielding at lower weight, allowing higher reentry velocities and increased payload capacity. Unlike PICA and Avcoat, which are heavy and difficult to manufacture, this TPS is produced using a resin film infusion (RFI) process, eliminating autoclave curing and streamlining production. These improvements directly enhance mission flexibility and cost efficiency. This technology also expands scientific research and technology demonstrations by enabling more instrumentation per flight and longer-duration experiments. It supports microgravity research, astrophysics, atmospheric science, and planetary entry validation. Sounding rockets often serve as testbeds for reentry and EDL technologies, such as the IRVE-3 inflatable heat shield, and this TPS can further support high-speed reentry experiments and planetary lander development. By improving thermal efficiency, reducing structural mass, and lowering operational costs, this innovation strengthens NASA’s suborbital flight capabilities. Its potential for increased reusability and TPS performance makes it a valuable asset for future high-altitude and planetary exploration missions. The lattice-based thermal mitigation skin offers significant applications beyond NASA, particularly in commercial spaceflight and non-aerospace thermal protection systems. As commercial rocket programs continue to expand, companies such as SpaceX, Blue Origin, Rocket Lab, and Sierra Space seek lightweight, cost-effective TPS solutions for reusable suborbital and orbital vehicles. The proposed technology’s low-density alumina lattice structure and ablative silica-phenolic coating provide superior thermal insulation and heat resistance, making it well-suited for high-speed reentry vehicles, upper-stage recovery, and next-generation crewed spaceplanes. Unlike traditional ablators, this mass-efficient TPS supports greater payload capacity and reduced refurbishment costs, critical factors for companies focused on reusability and high-flight cadence. Beyond rocketry, this innovation has potential in advanced hypersonic systems, including defense applications for hypersonic glide vehicles and high-speed atmospheric reentry platforms. The lightweight, high-temperature-resistant material can be integrated into thermal shielding for military aerospace systems, where extreme heat loads from hypersonic speeds require robust thermal protection. Additionally, non-aerospace industries can benefit from this high-performance TPS technology. Automotive manufacturers developing heat-resistant materials for electric vehicle (EV) battery enclosures could adopt the lattice structure for fireproof casings and thermal barriers. Industrial applications, such as high-temperature manufacturing equipment and energy systems, could use this TPS for heat shielding in furnaces, power plants, and extreme-environment machinery. The ability to withstand high temperatures while maintaining structural integrity makes it a versatile solution for diverse commercial and defense applications.

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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