An integrated multi-physics and multiscale modeling framework for simulating infusion and curing of Thermal Protection System (TPS) materials

This proposal introduces an integrated simulation framework designed to optimize the manufacturing of advanced thermal protection systems used in aerospace applications. The framework employs a multi-physics, multi-scale modeling approach that captures both the macro-level resin infusion and the micro-scale curing processes. It integrates commercial CFD (STAR-CCM+) and FEA (Abaqus) third party tools with AnalySwift’s proprietary micromechanics code, SwiftComp, to simulate complex phenomena such as variable porosity within 3D woven preforms, resin off-gassing, curing-induced shrinkage, and chemical kinetics. Funding will support the development of physics-based models, the creation of user-friendly software plugins, and experimental validation to ensure the accuracy of predicted infusion quality and structural performance. By reducing reliance on trial-and-error methods and streamlining process optimization, the resulting toolkit will lower production costs and accelerate design cycles for high-performance heat shield components. Target markets include both aerospace sectors and high-performance composite manufacturing industries, where precise process control is critical to ensuring reliability under extreme conditions.