Large Silicon Carbide Grids for X-Ray Microcalorimeter Blocking Filters

Our SiC grids address a NASA Tier 1 technology gap, Microcalorimeter Optical Blocking Filters. Phase II SiC grids will reduce blocking filter contamination rate by 100X and increase filter strength by 2X. The performance advantages we identify for SiC microcalorimeter grids have analogs for AXIS, and for X-ray instrumentation. Our fabrication technology will be used to make precision parts and micro-electrical mechanical systems (MEMS). We can create silicon carbide components with exceptional thermal properties, strength, and dimensional tolerance. The requested Phase II funding primarily advances the TRL of SiC grids by increasing their vibration strength 4-20X. This strength increase enables SiC grid implementation into X-ray telescopes, most notably AXIS and X-IFU. It will provide SiC grid durability test data to the AXIS team. The Phase II prototypes will allow us to bridge the gap from laboratory samples to prototypes for planned missions. The test data obtained in Phase II will reduce the OBF technical risks for other upcoming X-ray telescope missions. The Phase II funding assists our cost reduction goals by allowing us to make purchases of newly available higher performance components. To achieve the best results, we purchase factory lots of components and build these into our custom process tools. Our Phase II plan calls for purchasing three such factory lots, and will demonstrate a 6X cost reduction. Phase II will make fundamental advances in SiC component strength and materials damping. For example we will deposit a metal multilayer damping coating, a structure which never before been tested. This multilayer is expected to provide more damping than any previous deposited metal coating. Phase II will increase ceramic strength to a level which has never previously been demonstrated for large components.

X-ray instruments which could benefit from our technology include AXIS, newAthena X-IFU, Line Emission Mapper, Lynx LXM, Lynx HDXI, Surveyor, Cosmic Web Explorer, the International Axion Observatory(IAXO) , HEX-P, Theseus SXI and newAthena WFI. Other X-ray and EUV instruments, such as spectrometers on a great number of missions, could also benefit from SiC grids. Weather satellite instruments, including EUV imagers and particle detectors for GOES, VIGIL, and other weather satellites could benefit from SiC grids. Charged particle spectrometers such as the Autonomous Ion Mass Spectrometer Sentry (AIMSS) can benefit from the high transmittance, dimensional stability, and flatness of SiC grids. SiC membranes can be used in transducers monitoring high temperature, high density plasmas. Low-erosion, low-mass SiC grids can provide superior grids for ion beams and ion beam propulsion. We plan to enter the following commercial markets: A. Space Flight Programs (2025) SiC grids will replace steel and nickel grids, improving X-ray filter performance. B. Foil Supports and Electrostatic Grids (2027) SiC grids will replace grids made from other materials in a host of terrestrial applications. C. Micromachined Parts (2028) SiC machined parts will provide superior ceramic stiffness, strength, dimensional tolerance and thermal properties. D. SiC Membranes and Instrumented Windows (2030) SiC membranes will replace diamond and beryllium X-Ray windows. E. Etch Equipment for Machining, Semiconductor and MEMS (2031) We will ultimately make our technology available for other manufacturers for OEM manufacturing. These markets require successively lower cost. We can already produce SiC grids at a cost suitable for space programs. By 2027 our costs will have fallen to a level where we can profitably manufacture laboratory grids and foil supports to replace an existing constellation of these components. The value proposition throughout these applications will be superior performance without increased cost. Subsequently we will enter the micromachined parts market, taking advantage of the known superiority of SiC components while offering higher strength, better precision, and lower cost. We will also enter the SiC membrane market, offering a technically superior X-ray window compared to diamond and a safe alternative to beryllium. After entering these markets, we will enable other markets, such as general micromachining, MEMS, and semiconductor processing, by offering process equipment.

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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