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.