The purpose of sub-topic T12.05 is to demonstrate the ability to significantly improve the manufacturing processes of Thermal Protection Systems (TPS) used in human-rated spacecraft with the intention to reduce cost and improve system performance. New TPS materials and compatible additive manufacturing processes which allow deposition, curing, and bonding over large spacecraft areas are required for future NASA Human Exploration and Operations Mission Directorate (HEOMD) Lunar and Mars missions, and Science Mission Directorate (SMD) planetary missions which require hypersonic entry through an atmosphere.
During Phase 1 Goodman Technologies (GT) completed the following:
For Phase II, GT in partnership with the Hawaiian Nanotechnology Laboratory (HNL) at the University of Hawaii at Mānoa, (UHM, is a Minority Serving Institution) propose an Automated Robotic Manufacturing System (ARMS) capable of Additively Manufacturing (AM) purposefully engineered monolithic CFCNC TPS and Reusable Hot Structures. Our Silicon Carbide (SiC) based 3D printable and moldable nanopastes together with SiC (Hi-Nicalon) reinforced prepreg for the molding, curing and joining of Continuous Fiber Ceramic Nano-Composites (CFCNCs) overcomes the issues of delamination and segment separation and will have tremendous payoff for spacecraft TPS and hypersonics in general.
NASA New Frontier missions and in situ robotic science missions require heat shields and thermal protection systems for Venus probes and landers, Saturn and Uranus probes, and high-speed sample return missions from Comets and Asteroids. The Human Exploration and Operations Mission Directorate (HEOMD) is, of course, spearheading the efforts to expand a permanent human presence beyond low-Earth orbit, i.e., to the Moon and to Mars. Many large surface area TPS for spacecraft are needed.
Non-NASA applications of low cost, rapidly manufactured CFCNC TPS are Commercial Space Programs and Programs of Record for the Department of Defense. GT’s technology provides t a retrofit opportunity for missiles, missile fairings, aeroshells and other strategic air platforms and cruise missiles. The large Automated Robotic Manufacturing System will be portable to System Primes and OEMs.