Novel Fiber Optic, Non-Invasive Divert and Attitude Control System (DACS) Composite Overwrapped Pressure (COPV) Pressure Measurement System

Physical Sciences Inc. (PSI), in collaboration with Worcester Polytechnic Institute (WPI) and supported by Lockheed Martin Space, has developed a Fiber Bragg Grating (FBG) based method to accurately measure the internal pressure of Composite Overwrapped Pressure Vessels (COPVs). This innovative, non-invasive, and non-destructive solution meets the Missile Defense Agency's (MDA) need for a system deployable without removing the COPV from the Divert and Attitude Control System (DACS) or the DACS from the Missile Round (MR). Helium is not lost during measurement, maintaining the pressurant integrity essential for Terminal High Altitude Area Defense (THAAD) missile engagements. Phase I-equivalent feasibility studies demonstrated the prototype performance on both a stainless-steel pressure vessel at WPI and a COPV at PSI. During the proposed Phase II effort, PSI will develop, test and deliver a Gen-3 pressure sensor system. Year I will expand the 5-sensor Gen-1 system to 9 sensors, followed by a 20-sensor Gen-2 system for high-accuracy measurements. Year II includes collaborative testing at WPI and if available within the THAAD DACS assembly facility and the THAAD test area, informing the Gen-3 system. The final Gen-3 system will be validated and delivered to the MDA in Year II. Approved for Public Release | 25-MDA-12052 (27 Mar 25)