Single-Sided Tooling Infusion of Carbon-Carbon for Hypersonics (STICCH)

Dynovas’ Single-sided Tooling Infusion of Carbon-Carbon for Hypersonics (STICCH) process is cheaper and faster than traditional CVD C-C manufacturing with an increased yield and compatibility with multiple TPS reinforcement layup configurations and carbon precursor resins. Lockheed Martin and Raytheon both provided their support for the development of the technology. Dynovas’ partner, Sandia National Laboratories, rounds out the Dynovas team by delivering a history of C-C structure design, material and process development, characterization, and industry transition of hypersonic technologies. The STICCH structural manufacturing process builds on the Dynovas’ teams existing C-C manufacturing capacity via non-CVD, non-phenolic processes. Demonstration if carried through Phase I, II, III will be: Phase I – Material Characterization and Process Validation; Phase II – Flight Article Builds; Phase III – Production Stabilization and Hypersonic Test Flights. In Phase I, the Dynovas team will establish a repeatable, single-sided tooling, non-CVD C-C manufacturing process, demonstrate the STICCH process via production of a C-C panel, and verify panel quality through micro-CT void analysis, tensile testing, compression testing, short beam shear testing, and oxyacetylene torch ablation testing. In addition to improving the cost and lead time of C-C manufacturing, the STICCH approach has the potential to expand the C-C industrial base by significantly increasing the number of C-C suppliers. The STICCH process is accessible to the hundreds of American composite manufacturers with high pressure autoclave and high temperature furnace capabilities (or access). If successful, the Dynovas team sees the opportunity to support and pursue revenue from the on-going hypersonic R&D initiatives, delivery of C-C structures, and licensing of the STICCH process. The Dynovas team will work with OEM primes, the various defense agency customers, NASA, and the DLA in order to leverage our assets and resources toward commercializing the overall STICCH process.