A collaborative team from Oak Ridge National Laboratory and Sierra Space has engineered a revolutionary silicon-carbide-based thermal protection system (TPS) for reusable commercial spacecraft. This advanced material solution combines cutting-edge materials science with decades of NASA thermal protection experience to create a durable shield capable of withstanding multiple atmospheric re-entries.
Advanced Composite Material for Extreme Conditions
The innovative TPS merges silicon carbide’s exceptional temperature and corrosion resistance with carbon fiber’s structural integrity, creating a lightweight yet robust thermal barrier. This composite material system maintains dimensional stability under extreme heat while providing critical insulation—a significant improvement over traditional silica-fiber tiles that required painstaking custom fabrication for each spacecraft. The development draws on three decades of operational data from NASA’s Space Shuttle program, which utilized over 24,000 individually crafted tiles per orbiter.
Streamlined Manufacturing Process
Unlike the Space Shuttle’s labor-intensive tile production—which involved high-temperature sintering of silica mixtures at 2,350°C—the new TPS features:
- Standardized modular components reducing fabrication complexity
- Enhanced durability for multiple reuse cycles
- Lower-profile installation improving aerodynamics
- Patent-pending material composition
The team has completed initial material development and is now focusing on optimizing the manufacturing process for the insulative tile backing component.
Application in Commercial Spaceflight
Sierra Space plans to deploy this thermal protection technology on its DC100 Dream Chaser spaceplane, which will:
- Transport cargo to the International Space Station under NASA contract
- Support crewed missions to low-Earth orbit
- Enable cost-effective reusable space operations
The winged spaceplane design requires particularly robust thermal protection for its leading edges and undercarriage during atmospheric re-entry.
Advancing U.S. Space Manufacturing
This research, conducted at ORNL’s Manufacturing Demonstration Facility with DOE support, represents a significant leap in spacecraft materials technology. By developing reusable thermal protection systems through public-private collaboration, the project strengthens American leadership in commercial space infrastructure while reducing costs through improved manufacturing techniques.
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