Pintle Actuator for Hypersonic Defense (PAHD)

Electromechanical actuators (EMA) are utilized in every flight and propulsion control system within the aerospace system architectures. EMA technologies typically consist of Brushless Direct Current (BLDC) motors integrated with a drivetrain to produce a linear or rotary output motion. The size, weight, and power and cost (SWaP-C) characteristics that are achievable with a given EMA architecture are largely constrained by the maximum deliverable power density (i.e. torque output). The recently completed Phase I program conducted by Exo-Atmospheric Technologies, LLC (EXO) worked to develop a new processing technique to produce high performance wires suitable for Phase II scale-up. The proposed Phase II program will refine, optimize, scale-up, and verify that the process produces high-quality, consistent wires with a current capacity exceeding state-of-the-art using a novel wire processing technique. A set of custom hardware will developed to process the wire. Optical diagnostics will also be employed to verify the process meets specifications. The wire will then be coated with a high-temperature insulation material suitable for operation at high temperatures. The wire produced will be suitable for use in winding a prototype EMA. The actuator will be tested on a specialized test stand to measure its performance versus current state-of-the-art actuators. The actuator will then be integrated with a specialized drivetrain to test the actuator under realistic operating loads in a high temperature environment. Approved for Public Release | 25-MDA-12052 (27 Mar 25)