Unlocking Hypersonic System Performance with Transpiration-Cooled Thermal Protection Systems

“We have to get the cost down for hypersonic weapons – if we don’t, the services will move to adopt less effective but lower cost solutions” – a statement made in April 2024 by a senior leader within the Joint Hypersonic Transition Office (JHTO) is a keen reminder of the challenge to the national security industrial base. The DOD needs performance AND affordability, otherwise great inventions will be relegated to libraries of history where countless DAF and NASA hypersonic demonstrators from the 60s and 70s remain. This translates to an opportunity to enable truly performance-increasing solutions through new, advanced manufacturing technologies. Canopy Aerospace (“Canopy”), a veteran-owned, venture-backed company, aims to develop and commercialize innovative transpiration-cooled silicon carbide (SiC) thermal protection systems (TPS) for hypersonic and space applications. The company's primary objective is to address critical gaps in  the U.S. supply base for high-temperature materials and TPS, benefiting both national security and commercial space markets. This innovation leverages advanced additive manufacturing (AM) techniques to produce high-performance, reusable TPS materials suitable for the extreme conditions of hypersonic flight and space reentry. The AM process allows for rapid, cost-effective production of complex ceramic components. Canopy's 18,000 sq. ft. facility in Colorado houses next-generation ceramic 3D printers and scalable manufacturing solutions. The company's expertise and equipment enable the rapid development and production of state-of-the-art TPS. Previous funding from NASA and the USAF has supported advancements in these manufacturing techniques. The projected market for advanced TPS is estimated to reach $2.5 billion by 2030. Canopy’s primary customers include the USAF, United States Space Force (USSF), NASA, and commercial space companies. The company's innovative manufacturing techniques are expected to capture significant market share due to favorable unit economics and superior product performance. In Phase II, Canopy will collaborate with AFRL/RVBN, Texas A&M, and NASA Langley Research Center to advance its TPS technology over a 19-month period of performance that will conclude with projected flight readiness, including alignment with mission requirements and funding for Phase III technology transition. The transition strategy involves engaging with partners like AFLCMC Propulsion Directorate, Arnold Engineering Development Complex, AFRL, and demonstrating progress to facilitate integration into defense and commercial programs. Canopy Aerospace is set to transform the high-temperature materials and TPS market with its innovative transpiration-cooled SiC TPS. Supported by strong technical expertise, strategic partnerships, and significant funding, Canopy is well-positioned to meet the needs of both defense and commercial aerospace sectors, driving advancements in space exploration and national security.