Additive Manufacturing of Structural Insulators

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 simple and reliable. As designs evolve, there is a need for TPS insulation materials that can be additively manufactured. Our Phase I approach will additively manufacture pre-ceramic scaffolds that are used to create low density ceramic foams. The additive process will allow us to vary the pore size and density locally. 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. Approved for Public Release | 22-MDA-11339 (13 Dec 22)