3D Woven Thermal Protection - Weaving the Future of Space Exploration

Thermal protection systems (TPS) are vital components that protect spacecraft from the extreme heat generated during atmospheric re-entry. TPS has been one of the core disciplines in space exploration since the early days, and decades of research and development have accumulated a plethora of options to deal with different re-entry profiles, vehicle configurations, atmospheres, and launch constraints.

 

Some historic TPS are no longer viable, for example, carbon phenolic. This high-temperature phenolic matrix composite was used for the Galileo probe that entered the upper atmosphere of Jupiter, the most physically demanding use case of TPS yet. However, due to the cessation of Rayon fibre production (a key input for carbon phenolic), this heat shield is no longer a viable option for missions.

 

One technology touted as a possible advancement in the field of TPS is 3D woven materials, as explored in IDTechEx's report, "Heat Shields & Thermal Protection Systems for Spacecraft 2025-2035: Technologies and Market Outlook". This granular research report takes a deep dive into the discipline of TPS, examining both current, historic, and emerging options for TPS as well as exploring the changing nature of the space industry and how this will affect material requirements and development.

 

 

3D woven TPS uses precise placement of yarn fibres (either carbon or quartz) in combination with resin moulding to give enhanced resistance to delamination, and ablators that can have variable density and distinct functional layers. They can also be rigid or flexible, depending on the design requirements. This requires advanced textile manufacturing techniques, but the resulting weaves have already proven capable of challenging re-entry conditions.

 

HEEET (Heatshield for Extreme Entry Environment Technology) was a technology demonstrator program run by NASA that mechanically interlocked an outer layer of high-density carbon fibre weave with an inner insulation layer of blended carbon phenolic yarn. The woven material was infused with a phenolic resin, which is designed to 'ablate' under atmospheric re-entry. As a result of the unique weaving process, NASA was able to reduce the heat shield mass by 40%, in space travel, minimising launch mass in an essential parameter to maximise useful payload.

 

 

TPS is often a mechanically fragile, low-density material. This is usually advantageous, as lowering the density means more payload can be loaded onto the craft. However, there are certain key structural points where the TPS needs to also be exceptionally strong, for example, the pads that serve as the interface between the crew module and service module.

 

The TPS used at this point must carry the structural loads generated during launch and operation. And also fulfil the function of TPS during re-entry. NASA chose to use a 3D woven TPS for its significant structural capabilities and ability to withstand high aerothermal heating. 3D MAT (Multifunctional Ablative Thermal Protection System) was built and designed especially for Orion, which will return humans to the lunar surface as part of the Artemis program.

 

 

Although woven TPS has a large range of exciting benefits, its manufacturing is somewhat limited by the loom size, and making full-sized heat shields is a challenge that currently requires bonding together several tiles, with designing an appropriate gap-filler a key hurdle.

 

 

 

IDTechEx's report "Heat Shields & Thermal Protection Systems for Spacecraft 2025-2035: Technologies and Market Outlook" covers a variety of TPS options and illustrates the changing nature of the industry, showcasing how different materials apply to different use-cases. The report covers 3D wovens in the context of ablative systems, as well as exploring non-ablative tile-based systems and other disruptive technologies, such as inflatable heat shields.

 

For more information on this report, including downloadable sample pages, please visit www.IDTechEx.com/TPSSpacecraft, or for the full portfolio of thermal management-related research available from IDTechEx, see www.IDTechEx.com/Research/Thermal.