Wireless Smart Thermal Protection System (TPS) for USSF Space Vehicles

February 1, 2003 – the Columbia Space Shuttle, traveling 18x faster than the speed of sound, was heading back to Earth. Upon re-entry, the space shuttle reached temperatures of up to 2691 °F, and a critical failure of its Thermal Protection System (TPS) caused white-hot plasma to penetrate the shuttle, claiming the lives of the seven astronauts on board—a tragedy that could have been avoided. November 21, 2003 – the Space Shuttle has not flown since 2011, and the supply base for critical capabilities in the United States like thermal protection systems has dried up. This results not only in difficulty for the DOD to procure TPS, but a general lack of applied innovation normally spurred by commercial activity. Despite these supply chain constraints, the need for TPS within the defense industrial base and emerging commercial space economy has skyrocketed due to recent technological advances and the pacing threat of advanced nations like China. A DAF required innovation in TPS is the integration of wireless, ‘smart sensing,’ capabilities; the monitoring systems and real-time responsive data are critical to USAF/USSF vehicle systems and can keep Airmen and Guardians safe, ensuring mission integrity. Canopy’s wireless integrated sensors can monitor temperature and structural integrity of TPS, displacing the need for traditional wired sensors, leading to better predictive maintenance and real-time monitoring – reducing the risk of catastrophic failure. It's imperative that safety of flight be advanced for future space flight. Canopy will execute a 21-month Phase II effort to develop a prototype of the Smart Wireless TPS Sensor for AFRL/RV and qualify it via ground testing facilities in the United States. Canopy will study sensor-material compatibility, determine suitable manufacturing routes for embedding sensors, and design the hardware architecture. The project will culminate with simulated flight testing of the prototype, proving functionality through exposure to high aerothermal loading. The Phase II results will prove out key hypotheses related to better predictive maintenance – reduced catastrophic failure, increased performance, fuel efficiency, and overall increased safety of flight for vehicles. Afterward, Canopy’s Smart TPS technology will be ready for initial flight testing in 2025.