Sierra Space and Oak Ridge Lab develop advanced thermal protection for spacecraft

Sierra Space and Oak Ridge Lab develop advanced thermal protection for spacecraft
by Clarence Oxford
Los Angeles CA (SPX) Nov 15, 2024

Sierra Space has announced a significant advancement in thermal protection technology through its collaboration with the U.S. Department of Energy's Oak Ridge National Laboratory (ORNL). This development, featuring spacecraft tiles that can endure the intense heat of atmospheric re-entry for numerous missions, aims to support the increasing pace of commercial space travel. The new Thermal Protection System (TPS) is designed to meet the demands of modern spaceflight, which requires more frequent and reliable missions.

Drawing on expertise developed during NASA's Space Shuttle era, the joint team created a system that surpasses previous tile capabilities. While tiles on the Space Shuttle typically supported around five missions annually, the rapid evolution of commercial space travel calls for enhanced durability. The Dream Chaser spaceplane, built by Sierra Space and contracted with NASA for space station cargo delivery, is engineered for a minimum of 15 missions and features a nine-month refurbishment cycle.

"Today marks a new era of spaceflight safety technology, and it's going to enable travel to Low Earth Orbit that will eventually rival the frequency of commercial air travel," stated Sierra Space CEO Tom Vice. "Our patent-pending Thermal Protection System is like nothing ever before created and essential to a near future where space travel becomes routine. Reusability of space vehicles is a key factor in expanding the commercial space industry and to do that we need new technology to keep spacecraft and crew safe."

These TPS tiles are constructed from a unique composite material combining the strength of carbon fiber with the high-temperature resilience of ceramic components. They are designed to offer low-density thermal insulation necessary for protecting spacecraft while ensuring stable aerodynamics. Spacecraft re-entering the atmosphere face speeds exceeding Mach 17 (approximately 13,000 mph or 21,000 kph) and temperatures over 3,100 degrees Fahrenheit (1,704 degrees Celsius).

Greg Larsen, ORNL's group leader for extreme material environment processes, expressed enthusiasm for the project: "Every kid when they're growing up dreams of being involved in spaceflight in one way or another. To make a new material technology that has the potential to go to space over and over while advancing the U.S. space program is a real thrill. This is a great example of ORNL's focus on collaborating with industry by applying our deep materials development expertise to real-world industry challenges."

Having completed the initial phase of development, Sierra Space and ORNL are now preparing for further testing, which includes rigorous trials at NASA's Arc Jet plasma facility to replicate the conditions of atmospheric re-entry. This next phase will also involve exploring advanced manufacturing techniques aimed at reducing the cost of producing TPS tiles. The new system will be integrated into Sierra Space's fleet, including the upcoming spaceplane Reverence, currently under construction at their Colorado-based Dream Factory.