Light-weight and Low Cost Composite Cryotank Development using a Microcrack Resistant Resin System

DARPA has embarked on the Experimental Spaceplane (XS-1) program to facilitate rapid insertion of smallsat payloads at aircraft-like operational tempos. An enabling technology for minimizing the cost and maximizing the payload-to-space capability of XS-1is reusable, all-composite, liner-less (Type V) cryogenic tanks with very low mass fractions. DARPA has identified that current material limitations exist with respect to the cryogenic strength of composite materials for such tanks. They seek high-strain, cryogenically compatible, out-of-autoclave (lower cost) resin systems, which are the key to achieving tank weight/volumes for improved vehicle performance and payload delivery. In response, CTD is developing novel resin materials based on toughened epoxies to meet these goals and to exceed the performance of current state-of-the-art. The proposed Phase I programs end goal is to develop and validate these new high-strain capable materials, while advancing tank design to meet both the cost and mass per volume goals set forth by DARPA. This Phase I program seeks to leverage and build-upon CTDs industry-leading toughened cyrotank materials and to further develop and validate the ability to manufacture high-strain capable/microcrack resistant all-composite cryotanks exhibiting exceedingly high strength at low-cost.