Dynovas Advanced Pressure Resin Transfer Molding (DAP-RTM) for Large Three Dimensional Woven Preforms

NASA is progressing the development of thermal protection system (TPS) concepts using Large 3D-woven preform composites to facilitate both robotic and human space missions, particularly during entry and aerocapture phases. These advancements find application in missions to celestial bodies such as Mars, Venus, and Titan, as well as in suborbital missions and those returning to Earth. The woven preforms that serve as constituents for these new materials tend to have a high fiber density, large volume, and intricate weave patterns. These attributes have consistently shown that traditional resin transfer molding processes such as vacuum assisted resin transfer molding (VARTM) and vacuum resin film infusion (RFI) are incapable of achieving full densification (<2% void volume). The Dynovas Advanced Pressure Resin Transfer Molding (DAP-RTM) system specifically addresses NASA’s call for development of an improved and more reliable method to infuse NASA’s 3D Multifunctional Ablative TPS (3D-MAT) and other large three dimensional preforms. The DAP-RTM system provides a novel solution that leverages the extensive experience of the Dynovas staff in this technology area. The proposed development work plan will advance current state of the art, reduce schedule, increase yield, and reduce cost for Large Three Dimensional Woven Preforms Composites through implementation of three key process improvements: 1. Improved Resin Flow 2. Advanced Preform Preprocessing 3. Tailored Mechanical Injection