Additively Manufactured Low Cost Complex Shaped Upper Stage Propellant Tanks

NanoSonic has recently developed non-conventional metal-free, ultra-high pressure (burst strength > 33,000 psi) hydrogen (H2) dispensing hoses via additive manufacturing (AM) techniques for use at ultra-high pressures (> 875 bar) and over an extremely harsh service temperature range. We have since scaled our AM technique to demonstrate a 26-L leak-proof cryotank (the Chill Pill) for use with liquid rocket propellants (LOX, LH2, RP-1) for future DARPA spaceplanes. Our automated AM filament winding technique allows for the production of large (up to 21' long and up to 6' diameter) 3-D structures based on advanced materials that are not currently available in traditional composite pre-pregs. Here, NanoSonic offers AM filament wound pressure vessels as low cost upper stage propellant tanks to the MDA. The proposed tanks shall be designed to offer propellant storage in a singular modular primary complex shaped structure. In Phase I, NanoSonic shall optimize our AM method to develop composites suitable for space vehicle-structures with 1) improved volumetric efficiency and 2) maintained kinematic performance, and 3) multifunctionality as a propellant tank. We have worked with Lockheed Martin Missiles and Fire Control (LM MFC) on the sale of high performance materials for a non-related MDA funded effort. Approved for Public Release | 18-MDA-9817 (23 Oct 18)