Ultralight Micro-truss Cores for Space Launch Systems

HRL Laboratories, LLC, proposes a 12 month effort to develop an ultra-lightweight core material that has half or less the density of state-of-the-art honeycomb cores, while exceeding their mechanical properties. By combining our team's unique capability to manufacture ultralight micro-truss materials with our ability to design and optimize cellular architectures, we will achieve groundbreaking 40% mass reduction for sandwich structures for future aerospace vehicles. Our approach combines mechanically efficient, architected micro-truss templates with high-strength, nanocrystalline metal coatings. Both manufacturing steps involved, HRL's polymer micro-truss fabrication and electroplating of nanocrystalline coatings, are inherently scalable and cost-effective, ensuring that scale-up to large structures can be achieved, while meeting NASA's challenging cost target. We have already fabricated 12"x12"x0.5" ultralight micro-truss cores with a density of 2 lb/ft3 and superior properties to SOA honeycomb as well as curved micro-truss sandwich panels for ongoing development efforts. Under the proposed effort, we will mature and scale-up nanocrystalline metallic micro-truss cores for the next-generation of NASA's ultra-lightweight sandwich panels.

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.