Advanced Thermal Protection Concepts for Reentry Capsules

Thermal Protection Systems (TPS) are essential for enabling spacecraft to withstand the extreme heating that occurs during atmospheric reentry. When a capsule encounters hypersonic flow, the surrounding gas forms a high-temperature shock layer that can exceed several thousand degrees Celsius. TPS design must manage this heat load through a combination of insulation, controlled surface recession, internal energy absorption, and structural stability.

Early-stage research focus on multiple TPS architecture concepts and material system. These include 3-D woven composites, which offer integrated through-thickness reinforcement; honeycomb-reinforced structures, which enable tailored thermal response and lightweight mechanical support; resin-infiltrated preforms, which provide a pathway for conformal geometries and engineered porosity; and continuous fiber laminated composites, which allow precise control of anisotropic thermal and mechanical properties. Each architecture presents different trade-offs in manufacturing complexity, thermal performance, ablation behavior, and compatibility with capsule structural requirements.

The goal of this research is to build a foundational understanding of how these TPS concepts behave under high heat flux, how they manage pyrolysis and heat conduction, and how they can be integrated efficiently with composite capsule structures. This work supports the development of reliable, high-frequency reentry systems for future commercial and scientific missions.

[NASA Ref.]