Impact-Resistant, Damage-Tolerant Composites with STF Energy Absorbing Layers

We propose an innovative hybrid composite material containing shear thickening fluid (STF) Energy Absorbing Layers (SEALs) that provides superior impact protection and novel, self-healing functionality to prevent leakage after impact. The proposed innovation directly addresses the need for thin, lightweight, impact-resistant composite materials that can be fabricated in complex geometries for next-generation space suits. The proposed Phase II research leverages successful Phase I R&D and extensive composite materials and space suit expertise of our partners to advance commercialization and TRL of impact-resistant, damage-tolerant SEAL-composites innovation to produce a prototype suit component suitable for system-level integration and testing. In Phase I it was shown that the SEAL-composites provide significantly improved impact properties and weight savings vs. leading conventional composite materials from the Z-2 prototype.Futhermore, SEAL-composites impart self-healing functionality to mitigate air leakage if damaged. The Phase II objectives and work plan follow a logical sequence to test and downselect improved SEAL-composite materials, to develop and validate a computational model and conduct model-based design optimization, to develop high-fidelity test methods, to refine the manufacturing process to make aerospace-grade SEAL-composites, and to deliver a validated suit prototype component made from SEAL-composites. Further, we will leverage synergistic environmental protection garment (EPG) research being conducted at STF Technologies and the University of Delawareto perform system-level development and optimization of the SEAL-composites combined with emerging, state-of-the-art EPGs. Overall, the proposed Phase II will produce a validated SEAL-composite prototype suit component meeting the needs for improved impact-resistance and damage-tolerance to offer superior astronaut protection in a wide range of future Martian and Lunar surface EVA scenarios.