Additive-Manufactured Silicon Nitride Radomes (AMSNIR) for Next-Generation Hypersonic Systems

The DoD is placing a growing emphasis on developing hypersonic systems to maintain a competitive advantage in global security. These platforms operate in extreme conditions where conventional materials face performance limitations, particularly in protecting sensitive radar systems. Radomes, which shield these systems from high-speed aerodynamic heating and extreme thermal stress, must possess a combination of superior thermal, mechanical, and dielectric properties to ensure mission success.Canopy Aerospace (“Canopy”) is pioneering the development of advanced Silicon Nitride (SiN) radomes, specifically designed for hypersonic platforms. SiN offers a significant improvement over traditional radome materials like fused silica, providing higher thermal resistance (up to 1,400 °C), excellent mechanical strength, and optimal electromagnetic properties for radar transparency at high speeds. By utilizing additive manufacturing techniques, Canopy Aerospace can precisely control the microstructure of the SiN radome, tailoring its performance to meet the specific demands of hypersonic flight.In this 3-month Phase I project, Canopy will focus on optimizing the SiN radome manufacturing process and conducting a feasibility study in collaboration with the AFRL’s Materials and Manufacturing Directorate (AFRL/RX)  and Space Vehicles Directorate (AFRL/RV) to evaluate the radome's thermal, mechanical, and dielectric performance under hypersonic conditions. The project will provide critical insights into SiN’s potential to protect radar systems in the next generation of hypersonic platforms and will advance the technology towards TRL 5.