Multifunctional Composite Structures for Lightweight and Low Cost Exoatmospheric Miniature Interceptors

Miniature kill vehicle (MKV) interceptors can provide benefits to missile defense systems such as defense against discrimination and aim-point uncertainties for midcourse phase exoatmospheric intercepts of threat target complexes. The exoatmosphericminiature interceptor system approach includes multiple, small, low cost MKVs deployed from a larger carrier vehicle (CV). Each MKV, weighing about 1-2 kg with on-board sensor, guidance, and propulsion subsystems, allows end-game homing and kinetic killof specific targets in the target complex. Recent system concept studies project requirements for 10,000 MKVs with projected individual MKV structure cost goals in the $1,000-$2,000 range. These low cost goals will be difficult to achieve based onevolutionary approaches using the current EKV structures technology and heritage. Revolutionary advanced materials, design and manufacturing approaches are required, including high production rate manufacturing methods and alternatives to beryllium, whichis used extensively in the current EKV optical mirror, support structures, and other subsystems. Beryllium provides high performance, but is expensive and presents producibility issues for the projected high production rate for MKVs. A multifunctional MKVstructure concept is proposed in which the MKV structure provides multiple functions, such as structural, thermal, electrical, optical, and nuclear hardness, thus eliminating redundancy and reducing weight and costs compared to current design approaches.Alternative advanced metallic and composite materials, design approaches, and manufacturing methods, will be defined in Phase I design analytical trade studies, a full-scale prototype multifunctional MKV structure will be developed and ground testdemonstrated in Phase II, and an engineering development and demonstration would be conducted in Phase III as part of a system technology insertion program. Multifunctional MKV structure design concepts, including structural, thermal, electrical,optical, and nuclear hardness functions, will enable the MKV to meet the low mass fraction requirements and lightweight requirements for MKVs. Large volume production manufacturing methods that are compatible with advanced composite materials, such asResin Transfer Molding, will be used to meet the low cost and high production rate system requirements for the MKV system concepts. The anticipated benefit of the Phase I work is the development of a multifunctional MKV structure solution that meets theMKV system cost and weight goals.