Additive-Manufactured Ablative Thermal Protection Systems

To address the need for thermal protection systems with reduced cost and reduced complexity, with continuity over large areas, thermoset resin nanocomposite materials that are compatible with additive-manufacturing process will be optimized for thermal shielding applications. Additive manufacturing offers significant possibilities for developing and fabricating a thermal protection system (TPS); additive manufacturing can be used to realize heterogeneous structures with complex shapes, and additive manufacturing can be used to create a continuous coating across the surface of a vehicle, eliminating the seams between tiles that would otherwise present weak points in the protection.Nanocomposite thermoset resins will be designed for high temperature stability and char yield. The materials will be synthesized and fabricated, and the mechanical and thermal properties of the printed samples will be tested and shown to meet the application requirements.