In-Situ Application of Multi-Layer Thermal Protection System

Cornerstone Research Group Inc. (CRG) proposes to advance the state-of-the-art in space vehicle Thermal Protection Systems (TPS) through in-situ application and curing of a proprietary new resin technology called MG Resin, a family of thermoset formulations. The resins are being explored with DARPA, MDA, NASA, and the Army for a range of applications including C/C hot structures, TPS, syntactic insulation, and elastomeric rocket motor insulation among others. The materials have demonstrated high char yield, low erosion, and good mechanical performance, and are compatible with a wide variety of fillers and substrates. The overall material system is tunable to meet application, processing, and curing needs. Coupled with fillers, the resins allow a heat shield to be fabricated directly onto the vehicle and built up layer-by-layer for optimal performance to meet mission objectives. Inner layers can be filled with microballoons for insulation, outer layers filled with chopped fiber for strength, and the surface carbonized for improved ablation resistance. The hybrid materials are suitable for automated processing and the combined value is quicker and lower cost production of TPS for space exploration vehicles.