3D Printing of High Temperature Thermoset Foams for Space Vehicular Thermal Protection Systems

nbsp;Based on the knowledge and expertise gained in partnership with the University of Tennessee at Knoxville (UTK) during the NASA/STTR Phase I work, re:3D proposes the development of a pilot system for the deposition of a phenolic foam TPS surface onto a scaled demonstration article in parallel with refinements and improvements to the foamrsquo;s material characteristics.The Phase II research activities at UTK will focus on understanding the processing requirements to scale up production of the foam feedstock to 3D print large-scale test articles, refine the foam to further lower density and increase temperature stability, explore novel printing approaches to tailor effective density and elastic modulus and/or incorporate graded composition to raise temperature stability at the outer surface, and continued plasma arc jet torch testing of the developed materials and architectures.During Phase II, re:3D will be responsible for designing, developing and building the systems and mechanisms required for a pilot material extrusion system of the phenolic foam onto a scaled demonstration article consisting of an aluminum dome with a radius of curvature of approximately 1 meter and a 1-meter base diameter.nbsp; The system would be comprised of the following elements:Mixing of the foam components, either outsourced or performed in-house as determined by a feasibility study during the course of the Phase II investigation at UTKTransport of the foam from the mixing containers to the deposition nozzle through the use of an appropriate metering pumpConformal deposition of the foam onto the aluminum dome with in-situ defect monitoring and advanced motion planning using a gantry printer based on re:3Drsquo;s existing Terabot platform and a custom-designed extruder with added degrees of motionCuring of the foam in an appropriate industrial ovenPost-process machining to achieve the final desired finish of the TPS surface