Woven Thermal Protection System

manufacturing
Woven Thermal Protection System (TOP2-167)
Precisely engineered 3D weaving technique
Overview
NASA has developed a new technology for producing Woven Thermal Protection System (TPS) materials that uses precisely engineered 3D weaving techniques. The woven TPS approach utilizes commercially available weaving technology, consisting of equipment, modeling and design tools, to optimize the weave. Using woven TPS, sustainable, scalable, mission-optimized solutions can be achieved with relatively low life-cycle costs. Woven TPS leverages the mature state-of-the-art (SOA) weaving technology that has evolved from the textile industry to design materials with tailorable performance by varying material composition and properties via the controlled placement of fibers within a woven structure. The resulting material can be designed to perform optimally for a wide range of entry conditions encompassing NASAs current and future mission needs. Woven TPS enables these optimized designs to be translated precisely into mission- specific, manufactured materials that can dramatically increase the efficiency, utility, and robustness of heat shield materials compared to the current SOA material options.

The Technology
This invention presents a revolutionary approach to designing and manufacturing TPS materials using/augmenting design tools and infrastructure already in place in the weaving industry. Woven TPS is a concept that leverages the mature weaving technology that has evolved from the textile industry to design TPS with tailorable performance by varying a materials composition and properties by the controlled placement of fibers within a woven structure. The resulting woven TPS can be designed to perform optimally for a wide range of aerothermal environments encompassing NASAs future mission needs. The woven TPS approach can tailor a materials properties by the accurate placement of fibers of different composition with different spacings. This allows for the control of material composition and density in three dimensions, resulting in tailored material performance. Given that the constituent properties of the fibers are known, the performance of the material can be predicated with existing tools. In this way, a material can be optimized for a given mission. Testing will still be required to certify the final product for the mission, but this should substantially reduce the overall testing requirements and, hence, reduce the cost and schedule time.
Woven Thermal Protection Systems Woven Thermal Protection Systems
Benefits
  • Revolutionary approach to producing thermal protection systems
  • TPS material optimized for each mission
  • Reproducible and predictable material performance
  • Reduces mass margins and development/certification costs
  • Introduces robust new class of TPS materials to address future NASA mission needs
  • Woven TPS lowers development costs

Applications
  • Aerospace
  • Systems Engineering
  • Thermal Management Systems
  • Manufacturing Technologies
Technology Details

manufacturing
TOP2-167
ARC-16797-1
10,604,872
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