Additive Manufacturing of TPS Materials

There is a need for a lightweight, high-performance, insulation to protect the internal systems in hypersonic vehicles. A passive thermal protection system (TPS) design would be simpler and more reliable than a complex design that requires transport of fluids. As designs evolve, there is a need for TPS insulation materials that can be additively manufactured. Our Phase I research showed we can additively manufacture pre-ceramic scaffolds that are used to create low density ceramic foams with low thermal conductivity and high strength. In Phase II, the additive process will allow for functionally graded pore designs. This will allow the ceramic foams to perform structurally along predicted load pathways. Because they utilize additive manufacturing, they can be formed into complex insulation geometries that are more efficient than traditional foams. This will allow for designer pore structures that are optimized for thermal and structural loads. Processes will be scaled-up and tested on relevent geometries. Approved for Public Release | 24-MDA-11673 (8 Jan 24)