Oak Ridge National Laboratory (ORNL) and Sierra Space Corporation have developed a new thermal protection system (TPS) for commercial spacecraft. This system, made from silicon carbide and carbon fiber, is designed to withstand the intense heat of re-entry into Earth's atmosphere multiple times. Greg Larsen, the lead researcher at ORNL, emphasized that the TPS can maintain its aerodynamic performance after several flights, making it key to ensuring spacecraft reusability, according to the Oak Ridge National Laboratory website.
The new TPS composite material is designed to handle high temperatures and resist corrosion, making it ideal for spacecraft that need to last longer. It also maintains a consistent shape, ensuring aerodynamics aren’t affected after repeated exposure to intense heat. Drawing from 30 years of experience with NASA’s Space Shuttle program, the ORNL team has developed a more efficient, sustainable system. Unlike the shuttle's complex tile installation, this new TPS is easier to maintain and better suited for the fast-paced demands of today’s commercial space flights, allowing for quicker launch turnarounds.
ORNL and Sierra Space have filed a joint patent for their new TPS material. Now, they are focusing on improving manufacturing processes for the insulative tile backing to keep up with the fast-growing space industry. The new TPS will be used on the Sierra Space Dream Chaser, the first winged commercial spaceplane. This spaceplane, designed to transport both crew and cargo to low-Earth orbit, will use the TPS to improve payload efficiency and extend the vehicle's lifespan, according to Greg Larsen, as he told the Oak Ridge National Laboratory website.
Research on the TPS takes place at DOE's Manufacturing Demonstration Facility (MDF) at ORNL, a hub sparking innovation and bolstering the transformation of U.S. manufacturing. Both Sierra Space and ORNL continue to forefront the commercialization of space through technological feats and collaboration, contributing to an ecosystem ripe with potential for discoveries that could notably impact life on Earth. Sierra Space, with its track record of over 500 missions, is pushing into the Orbital Age™ with initiatives like the Dream Chaser and their LIFE™ platform, intending to enhance human habitation and research capabilities in space.
