2330355
Project Grant
Overview
Grant Description
Sbir phase I: 3D printing reentry capsules -the broader impact/commercial potential of this i small business innovation research (SBIR) phase I project is to accelerate humanity?s utilization and exploration of space. The international space station spends $1 billion annually on cargo transport but has limited opportunities for payload return each year. This bottleneck is caused by outdated reentry vehicle production that hinders microgravity research and in-space manufacturing developments.
The problem is becoming more pressing as commercial space stations are expected to increase space cargo return demand significantly in the next decade. By using 3-dimensional (3D) printing, manufacturing and refurbishment of entire reentry capsules (both the structure and heat shield) is 10 times faster and an estimated 95% lower in cost compared to traditional manufacturing. This innovative 3D printing solution will increase the cadence and lower the cost of space station cargo resupply and return, promoting the development of a robust low Earth orbit economy.
Frequent returns of high-value payloads from space will have substantial impacts on several industries including pharmaceuticals, semiconductors, fiber optics, etc. The technology will also provide rapid low-cost development of vehicles for various atmospheric entry or hypersonic applications including space resource return, deep space probes, rapid global delivery, hypersonic flight testing, and more. This SBIR phase I project will develop 3D printing of high-strength heat shield materials.
The research will test 3D printed specimens to demonstrate the feasibility of the first ever, entirely 3D printed capsules capable of surviving reentry from space. The core innovation is a platform technology that will be capable of rapid, large-scale, direct ink write 3D printing of aerospace-grade thermoset composite paste materials for the first time. To achieve this, the commercially available and widely proven thermoset resins will be cured directly at the point of deposition in seconds using a novel rapid heating method.
These materials typically require hours in an oven to cure, so the project is expected to demonstrate curing the highest-performing aerospace-grade materials faster than they have ever been cured before. This in-situ curing direct ink write 3D printing innovation will be a breakthrough in aerospace composite manufacturing. The composite formulations used in the project will be made of the same raw materials as used on flight-proven reentry capsule heat shields, but tailorable to be as strong as aluminum at half the weight.
The composites will perform as both the structure and heat shield on reentry capsules. This award reflects NSF's statutory mission and has been deemed worthy of support through evaluation using the foundation's intellectual merit and broader impacts review criteria.- subawards are not planned for this award.
The problem is becoming more pressing as commercial space stations are expected to increase space cargo return demand significantly in the next decade. By using 3-dimensional (3D) printing, manufacturing and refurbishment of entire reentry capsules (both the structure and heat shield) is 10 times faster and an estimated 95% lower in cost compared to traditional manufacturing. This innovative 3D printing solution will increase the cadence and lower the cost of space station cargo resupply and return, promoting the development of a robust low Earth orbit economy.
Frequent returns of high-value payloads from space will have substantial impacts on several industries including pharmaceuticals, semiconductors, fiber optics, etc. The technology will also provide rapid low-cost development of vehicles for various atmospheric entry or hypersonic applications including space resource return, deep space probes, rapid global delivery, hypersonic flight testing, and more. This SBIR phase I project will develop 3D printing of high-strength heat shield materials.
The research will test 3D printed specimens to demonstrate the feasibility of the first ever, entirely 3D printed capsules capable of surviving reentry from space. The core innovation is a platform technology that will be capable of rapid, large-scale, direct ink write 3D printing of aerospace-grade thermoset composite paste materials for the first time. To achieve this, the commercially available and widely proven thermoset resins will be cured directly at the point of deposition in seconds using a novel rapid heating method.
These materials typically require hours in an oven to cure, so the project is expected to demonstrate curing the highest-performing aerospace-grade materials faster than they have ever been cured before. This in-situ curing direct ink write 3D printing innovation will be a breakthrough in aerospace composite manufacturing. The composite formulations used in the project will be made of the same raw materials as used on flight-proven reentry capsule heat shields, but tailorable to be as strong as aluminum at half the weight.
The composites will perform as both the structure and heat shield on reentry capsules. This award reflects NSF's statutory mission and has been deemed worthy of support through evaluation using the foundation's intellectual merit and broader impacts review criteria.- subawards are not planned for this award.
Awardee
Funding Goals
THE GOAL OF THIS FUNDING OPPORTUNITY, "NSF SMALL BUSINESS INNOVATION RESEARCH (SBIR)/ SMALL BUSINESS TECHNOLOGY TRANSFER (STTR) PROGRAMS PHASE I", IS IDENTIFIED IN THE LINK: HTTPS://WWW.NSF.GOV/PUBLICATIONS/PUB_SUMM.JSP?ODS_KEY=NSF23515
Grant Program (CFDA)
Awarding / Funding Agency
Place of Performance
Kansas City,
Kansas
66103-3513
United States
Geographic Scope
Single Zip Code
Raven Space Systems was awarded
Project Grant 2330355
worth $275,000
from National Science Foundation in December 2023 with work to be completed primarily in Kansas City Kansas United States.
The grant
has a duration of 5 months and
was awarded through assistance program 47.084 NSF Technology, Innovation, and Partnerships.
The Project Grant was awarded through grant opportunity NSF Small Business Innovation Research / Small Business Technology Transfer Phase I Programs.
SBIR Details
Research Type
SBIR Phase I
Title
SBIR Phase I: 3D Printing Reentry Capsules
Abstract
The broader impact/commercial potential of this I Small Business Innovation Research (SBIR) Phase I project is to accelerate humanity’s utilization and exploration of space. The International Space Station spends $1 billion annually on cargo transport but has limited opportunities for payload return each year. This bottleneck is caused by outdated reentry vehicle production that hinders microgravity research and in-space manufacturing developments. The problem is becoming more pressing as commercial space stations are expected to increase space cargo return demand significantly in the next decade. By using 3-dimensional (3D) printing, manufacturing and refurbishment of entire reentry capsules (both the structure and heat shield) is 10 times faster and an estimated 95% lower in cost compared to traditional manufacturing. This innovative 3D printing solution will increase the cadence and lower the cost of space station cargo resupply and return, promoting the development of a robust low Earth orbit economy. Frequent returns of high-value payloads from space will have substantial impacts on several industries including pharmaceuticals, semiconductors, fiber optics, etc. The technology will also provide rapid low-cost development of vehicles for various atmospheric entry or hypersonic applications including space resource return, deep space probes, rapid global delivery, hypersonic flight testing, and more.
This SBIR Phase I project will develop 3D printing of high-strength heat shield materials. The research will test 3D printed specimens to demonstrate the feasibility of the first ever, entirely 3D printed capsules capable of surviving reentry from space. The core innovation is a platform technology that will be capable of rapid, large-scale, direct ink write 3D printing of aerospace-grade thermoset composite paste materials for the first time. To achieve this, the commercially available and widely proven thermoset resins will be cured directly at the point of deposition in seconds using a novel rapid heating method. These materials typically require hours in an oven to cure, so the project is expected to demonstrate curing the highest-performing aerospace-grade materials faster than they have ever been cured before. This in-situ curing direct ink write 3D printing innovation will be a breakthrough in aerospace composite manufacturing. The composite formulations used in the project will be made of the same raw materials as used on flight-proven reentry capsule heat shields, but tailorable to be as strong as aluminum at half the weight. The composites will perform as both the structure and heat shield on reentry capsules.
This award reflects NSF's statutory mission and has been deemed worthy of support through evaluation using the Foundation's intellectual merit and broader impacts review criteria.
Topic Code
SP
Solicitation Number
NSF 23-515
Status
(Complete)
Last Modified 12/21/23
Period of Performance
12/15/23
Start Date
5/31/24
End Date
Funding Split
$275.0K
Federal Obligation
$0.0
Non-Federal Obligation
$275.0K
Total Obligated
Activity Timeline
Additional Detail
Award ID FAIN
2330355
SAI Number
None
Award ID URI
SAI EXEMPT
Awardee Classifications
Small Business
Awarding Office
491503 TRANSLATIONAL IMPACTS
Funding Office
491503 TRANSLATIONAL IMPACTS
Awardee UEI
ZJNJLNVGYLM5
Awardee CAGE
8MD78
Performance District
KS-03
Senators
Jerry Moran
Roger Marshall
Roger Marshall
Modified: 12/21/23