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

We propose to create an open-source modification of our commercially available, affordable, industrial 3D printer, and in conjunction develop printable, high temperature hybrid thermosetnbsp;(HT2) materials in partnership with the University of Tennessee at Knoxville (UTK) during this Phase 1 NASA/STTR.In addition to additive manufacturingrsquo;s (AM) benefits of low-cost prototyping, efficient low volume manufacturing, and unparalleled ability to create complex geometries, utilizing the Gigabot platform offers scalability as research progresses to enable affordable and large-scale printing of TPS. The methodology proposed will have the potential of expanding the thermoset extrusion material library and significantly decrease the time spent on previous TPS systems.In collaboration between re:3D and UTK, HT2 Materials will be developed, and 3D printed with the target application of TPS for space vehicles. The TPS materials and methods will allow for optimum performance of extreme materials, making it possible to print them in more complex and contoured geometries to enable maximum heat shielding performance in space vehicular applications in launch and recovery. nbsp;This will involve the formulation of a three-phase, low-density, epoxy-polysilazane based syntactic foam, including high-alumina cenospheres and nanoclay reinforcement. The optimum material formulation will be paired with the CNC controlled movement of an extrusion head to enable tailored density and porosity control coupled with long pot life and several curing options to meet post-processing constraints. Various geometries will then be tested to demonstrate the optimized 3D printing parameters and resolution. The various parts that will be designed and fabricated will then be tested for their thermo-mechanical properties, extreme heat and flame resistance, and charring and ablation properties.