Ballistic Missile System Composite Integrated Missile Harness Fairing Assembly

Next generation interceptor missiles are designed to intercept incoming ballistic missiles during the launch portion of flight when the rocket plume is relatively easy to track. Achieving the burnout velocity with current rocket motor technology (i.e., three stages) presents an aggressive low weight challenge for the missile fuselage structures. The payload antennas provide the datalink between the payload and the command units prior to separation from the booster. Traditional window materials cannot withstand the aerodynamic heating environments. San Diego Composites LLC completed a Phase I SBIR program to demonstrate a Next Generation Interceptor Missile Fuselage with Integral Radome. The Phase I program identified survivable antenna window materials, demonstrated integration of the antennas and window with the thermal protection and structural layers, and presented manufacturing and assembly methods that minimize secondary operations. Analysis of several TPS candidates was performed to evaluate which combination of substructure and TPS materials provided the lowest weight solution. The Phase II focus will be on subscale component testing, full-scale manufacturing demonstration through low cost tooling and design validation testing with the goal of technology insertion to a prime contractor.