Supply Chain Logistics of Manufactured TPS Materials

Through this DLA STTR program, NanoSonic and Penn State will work with a major US manufacturer of missile systems and hypersonic vehicles. Together we will demonstrate automated filament winding and resin transfer molding manufacturing processes to produce high temperature thermal protection system (TPS) materials and evaluate material properties to develop production statistics and quality control methods. We will consider the supply chain logistics associated with sourcing ultra-high temperature ceramic matrix composite material precursors from domestic vendors. NanoSonic’s TPS fabrication process uses a low-cost polymer-derived ceramic resin and ceramic insulating structural fibers and fabrics. The materials are consolidated into environmentally robust silicon oxycarbide nanocomposites at low initial processing temperatures. Testing has been performed using quartz lamps, arc jet testing, and high temperature laser irradiation. During Phase I, NanoSonic shall develop estimates of precursor availability and delivery times and manufacturing times and costs, investigate material reproducibility, develop practical measurement-based means for quality control, and create initial statistics concerning the variability of material properties in large sample sets. NanoSonic and our large company partner have discussed a plan for transition of this technology to their manufacturing facilities.