Results for “research and development” — Page 20

NASA NTRSDate not supplied

Accelerating SNP Development with Radiation Source Approximations for Far-Field Environment Modeling

The successful development and deployment of space nuclear power and propulsion technology requires a high-fidelity, efficient means of modeling ex-core radiation fields. Monte Carlo particle transport codes provide enable the highest level of fidelity in radiation field modeling but are inefficient for modeling ex-core radiation without modification. This paper details the development of an approach to ex-core radiation field modeling that maintains the fidelity of a Monte Carlo transport approach without sacrificing computational efficiency. This approach is based on recent improvements to an existing Monte Carlo transport acceleration technique known as surface source banking. As the transport of many particles is required to ensure adequate uncertainty in far field transport, analytical reconstruction techniques are employed to represent surface source banks as sampleable series of distributions in particle phase from which an arbitrarily large number of particles can be generated and simulated. All steps of this approach are incorporated into an AMA model to test both the underlying mathematics of the analytical source reconstruction process, as well as the relevance of the technique as a whole towards SNP applications. These tests demonstrated that this approach is capable of accelerating far-field radiation modeling in SNP-relevant scenarios by factors of at least nine over purely eigenvalue-based scenarios without significantly sacrificing simulation accuracy.

Surface Source Banking↗

NASA NTRSDate not supplied

NASA Small Spacecraft and Distributed Systems: Recent and Upcoming Technology Demonstrations and Development Efforts

NASA’s Small Spacecraft & Distributed Systems (SSDS) program strengthens U.S. ability to conduct unique missions by rapidly developing and demonstrating capabilities for SmallSat exploration, science, and commercial space. In collaboration with NASA Centers, other government agencies, commercial industry, and academia, SSDS advances next generation SmallSat technologies like power, processing, propulsion, communications, autonomous navigation, architectures (swarms), and applications (AI/ML/Edge Computing)—to extend missions beyond LEO into cislunar and planetary space. Various investment mechanisms exist for SSDS to select and fund projects that will ultimately advance NASA’s Moon to Mars Architecture. Presented here are the latest achievements and findings from recently completed SSDS projects, along with updates from ongoing efforts and planned future work. Successful missions like Starling and CAPSTONE continue to demonstrate their capability after several years on-orbit. Advancements in next generation swarm configurations are being implemented by Starling for space traffic monitoring and management applications. Findings from recent SSDS flight projects are discussed: DiskSat, a unique SmallSat platform alternative to canisterized nanosatellites, launched December 2025 and is gathering data; the PTD series of missions concluded in December 2025. Current SSDS efforts are focused on addressing NASA Shortfalls relating to rendezvous and proximity operations, neuromorphic computing, and space situational awareness.

Roger Hunter↗

NASA NTRSDate not supplied

Design, Development, and Test of the Advanced Apollo Orbital Assembly System

As spaceflight moves toward commercial solutions for Crew Vehicles and Space Stations, opportunity exists to lower costs with novel designs. Probe and cone docking systems provide a lightweight, low cost, and high-performance docking solution. This work revisits the Apollo probe and cone design and modifies it for the requirements of today’s computer-controlled spacecraft. This new system is called the Advanced Apollo Orbital Assembly (APOA) system, and is intended to support satellite, cargo, and space station assembly missions. A simulation of the APOA was programmed, components were sized, and a design was created by scaling the probe to the size of an EELV Secondary Payload Adapter (ESPA) tunnel. Prototype test hardware was 3D printed using Fused Deposition Modeling (FDM) methods with Polylactic Acid (PLA) material. Testing of the APOA-ESPA was conducted at Marshall Space Flight Center’s (MSFC) Flat Floor, and a test-correlated simulation is used to evaluate a Monte-Carlo of Initial Contact Conditions (ICC’s) to establish baseline performance. The successful development, test, and correlation of the APOA-ESPA proves the design validity and increases Technology Readiness Level (TRL) from 2 to 4. This work opens the door to construction of an APOA-ESPA from flight like materials, and to develop a larger scale prototype APOA. When the full scale APOA is incorporated with the Common Berthing Mechanism (CBM), becomes the Hybrid Berthing System (HBS), which allows for berthing without a robotic arm.

Berthing↗

NASA NTRSDate not supplied

NASA Small Spacecraft and Distributed Systems Program - Recent and Upcoming Technology Demonstrations and Development Efforts

NASA’s Small Spacecraft & Distributed Systems (SSDS) program strengthens U.S. ability to conduct unique missions by rapidly developing and demonstrating capabilities for SmallSat exploration, science, and commercial space. In collaboration with NASA Centers, other government agencies, commercial industry, and academia, SSDS advances next generation SmallSat technologies like power, processing, propulsion, communications, autonomous navigation, architectures (swarms), and applications (AI/ML/Edge Computing)—to extend missions beyond LEO into cislunar and planetary space. Various investment mechanisms exist for SSDS to select and fund projects that will ultimately advance NASA’s Moon to Mars Architecture. Presented here are the latest achievements and findings from recently completed SSDS projects, along with updates from ongoing efforts and planned future work. Successful missions like Starling and CAPSTONE continue to demonstrate their capability after several years on-orbit. Advancements in next generation swarm configurations are being implemented by Starling for space traffic monitoring and management applications. Findings from recent SSDS flight projects are discussed: DiskSat, a unique SmallSat platform alternative to canisterized nanosatellites, launched December 2025 and is gathering data; the PTD series of missions concluded in December 2025. Current SSDS efforts are focused on addressing NASA Shortfalls relating to rendezvous and proximity operations, neuromorphic computing, and space situational awareness.

Roger C Hunter↗

NASA NTRS2026

Development of the Orion Life-Support Integration Facility (OLIF)

Testing the life support hardware of a vehicle that is going to take humans beyond low-Earth orbit (LEO) in conditions similar to space is crucial. The Orion Life-Support Integration Facility (OLIF) at NASA Johnson Space Center (JSC) was designed and built to test the Orion vehicle’s hardware and software as integrated systems to provide a complete Environmental Control and Life Support System (ECLSS) system-level qualification. The existing 11 Foot human rated vacuum chamber has been adapted to accommodate and integrate various qualification and flight like components of the Orion vehicle’s Air Revitalization System (ARS), Pressure Control System (PCS), Active Thermal Control System (ATCS) and the Orion Crew Survival System Suits (OCSS). The ultimate goal was to create an analog testbed that could safely support up to four test subjects in open “shirt-sleeve” or closed suit loop configurations and simulate Orion Cabin conditions. This integrated hardware/software ARS and PCS will help identify any technical issues that should be addressed prior to the Artemis-2 mission. This paper will discuss the history of Orion ECLSS hardware development testing in the 11 Foot Chamber, the challenge of integrating flight hardware and software control systems, and the capabilities that make it a unique, world class facility for NASA. It will provide an overview of past and future testing, and the lessons learned along the way.

Peter A Masi↗

NASA NTRSDate not supplied

3D Woven Mid-Density Carbon Phenolic (3MDCP) Full-Scale Heatshield Development for Mars Sample Return (MSR) Earth Entry System (EES)

The Mars Sample Return (MSR) mission will be returning samples of Martian soil to Earth. The samples will be returned in the Earth Entry System (EES). The EES capsule is protected by a new thermal protection system; the 3-Dimensionally Woven, Mid-Density, Carbon Phenolic (3MDCP) material which is derived from the Heatshield for Extreme Entry Environment Technology (HEEET). The baseline 3MDCP design is a single piece thermal protection system that avoids the manufacturing and certification challenges associated with a tiled configuration. A 3MDCP heatshield begins as a flat woven preform that is formed to the final heatshield shape and then infused with phenolic resin. A NASA Ames lead team, in collaboration with Spirit Textiles (formerly TEAM Inc.), Fiber Materials Inc. (FMI, a Spirit AeroSystems Company), and Kratos SRE, has been developing and demonstrating the processes to fabricate the 3MDCP heatshield and characterize the resulting properties. The process of forming the flat woven preform into the final heatshield shape, a sphere-cone geometry with a 52.5° cone angle, involves local but substantial movement of the yarns in the weave. This results in continuous fibers across the single piece heatshield, albeit with property variations between different regions of the heatshield. This presentation will provide a high-level status of 3MDCP development for the MSR EES heatshield. This will include an overview of the manufacturing processes with an emphasis on the impact of forming on fiber orientation, material properties, and performance. Results comparing preliminary formed and flat materials will be shown. Additionally, the presentation will layout the broader plan for property testing and tie-in to aerothermal performance.

Peter Edward Marshall↗

NASA NTRSDate not supplied

An Efficient Approach to Collect Inlet Characterization Data

This report considers a novel process to acquire performance data for supersonic mixed compression inlets that is faster, and therefore less costly, than the previous one. In the previous process, measurements were recorded in discrete increments. The backpressuring actuator was advanced, there was a pause to allow for airflow fluctuations to diminish, and then the measurements were recorded. While this process was methodical, reliable and accurate, it consumed significant wind-on time. In general, high-speed wind tunnels are expensive to operate considering maintenance, energy and human resource requirements. Furthermore, many facilities, such as blowdown wind tunnels, are limited in the duration that they can maintain the desired test condition. Consequently, a quick method to collect the measurements is desired. A favored approach has the actuator moving in a continuous fashion with measurements recorded as the actuator continuously progresses through the increment points. This approach, identified as the dynamic inlet characteristic data acquisition procedure, uses in situ dynamic high-speed pressure sensors to measure pressure signals. While faster, continuous movement adds dynamic effects to the data. To better understand these dynamic effects and other potential influences, a study was undertaken to compare wind tunnel measurements taken at discrete actuator position points with data gathered during continuous actuator movement. Specially, plots of inlet pressure recovery versus mass capture ratio, or total pressure characteristic curves, were examined. The data were measured during experiments in the NASA Glenn Research Center Abe Silverstein 10- by 10-Foot Supersonic Wind Tunnel (SWT) with an inlet propulsion test article. In this report, the wind tunnel experiment and the study objectives are described. The processes to reduce the data and for analysis are explained. A discussion of the results along with features noted in the data is given. Finally, conclusions from this study that may be used to guide future wind tunnel experiment planning are presented.

Inlet↗

NASA NTRSDate not supplied

An Efficient Approach to Collect Inlet Characterization Data

This report considers a novel process to acquire performance data for supersonic mixed compression inlets that is faster, and therefore less costly, than the previous one. In the previous process, measurements were recorded in discrete increments. The backpressuring actuator was advanced, there was a pause to allow for airflow fluctuations to diminish, and then the measurements were recorded. While this process was methodical, reliable and accurate, it consumed significant wind-on time. In general, high-speed wind tunnels are expensive to operate considering maintenance, energy and human resource requirements. Furthermore, many facilities, such as blowdown wind tunnels, are limited in the duration that they can maintain the desired test condition. Consequently, a quick method to collect the measurements is desired. A favored approach has the actuator moving in a continuous fashion with measurements recorded as the actuator continuously progresses through the increment points. This approach, identified as the dynamic inlet characteristic data acquisition procedure, uses in situ dynamic high-speed pressure sensors to measure pressure signals. While faster, continuous movement adds dynamic effects to the data. To better understand these dynamic effects and other potential influences, a study was undertaken to compare wind tunnel measurements taken at discrete actuator position points with data gathered during continuous actuator movement. Specially, plots of inlet pressure recovery versus mass capture ratio, or total pressure characteristic curves, were examined. The data were measured during experiments in the NASA Glenn Research Center Abe Silverstein 10- by 10-Foot Supersonic Wind Tunnel (SWT) with an inlet propulsion test article. In this report, the wind tunnel experiment and the study objectives are described. The processes to reduce the data and for analysis are explained. A discussion of the results along with features noted in the data is given. Finally, conclusions from this study that may be used to guide future wind tunnel experiment planning are presented.

Data Acquisition↗

NASA NTRSDate not supplied

Development of an Additively Manufactured Subscale Secondary Sealed Container for the NASA FROSTE Project

This presentation details the development of an additively manufactured (AM) subscale test article for the secondary sealed container (SSC) as part of the NASA FROSTE project. FROSTE is focused on the collection of regolith samples from shadowed regions of the Moon and the preservation of those samples at cryogenic temperatures for return to Earth. Our team was integrated into the FROSTE program to leverage innovative design approaches and additive manufacturing capabilities in support of a scalable development strategy, where the subscale configuration serves as the development path toward a full-scale SSC. Scalmalloy was selected as the primary material for all AM components due to its favorable strength-to-weight ratio, thermal conductivity, and demonstrated performance in aerospace applications. Its aluminum-based composition supports robust mechanical behavior at cryogenic temperatures while enabling efficient heat transfer and control of thermal gradients within the containment system. The SSC architecture consists of an outer container assembly that houses a phase change material (PCM) tank, which in turn contains primary containers holding the regolith. Thermal management relies on controlled conductive and radiative heat transfer, including a thermal connection assembly that interfaces the PCM tank to an external cryocooler via a thermal strap, and IMLI surrounding the PCM tank to inhibit radiative heat transfer. The outer container assembly incorporates sealing interfaces, thermal connection ports, and I/O feedthroughs, with PTFE spring seals used at critical interfaces to maintain containment integrity. The PCM tank is manufactured as a single monolithic Scalmalloy component and incorporates an integral lattice structure to minimize thermal gradients, internal channels for thermocouple routing, and interface features for thermal connection assembly integration. The tank is centrally suspended within the outer container using support rings, with G10 insulating components employed to inhibit thermal leaks. This work describes the design methodology, AM approach, and key considerations used to inform the design.

regolith↗

NASA NTRSDate not supplied

Preliminary Findings of the Experimental Development Unit Cold Flow Test for a Generation Zero Nuclear Propulsion Engine

Nuclear thermal propulsion (NTP) technology will greatly benefit human travel to Mars by significantly shortening transit times, improving crew safety, and providing more mission flexibility than traditional chemical rockets. As part of DRACO follow-on work to develop, build, and fly a generation zero NTP engine, a full scale flight-like experimental design unit (EDU) reactor was constructed to collect sufficient on-ground performance data to characterize flow induced vibrations (FIV) of critical reactor structures/components, inform development of the engine and reactor control algorithm, and collect pressure drop and flow distribution data across the reactor. The fluid conditions for the test program were designed to achieve system responses equivalent to that of an operational engine through all phases of engine operation including reactor startup, mainstage operation, reactor shutdown, and reactor cooldown. Over 100 tests were executed, flowing either GN2 or GHe through the EDU at varying flow rates and pressures. This experiment provided early validation of flow behavior and vibration risks before nuclear testing, boosted critical subsystem TRLs, informed design iterations, and reduced future test costs. The steady-state flow parameters for the experiment were modeled in Ansys Thermal Desktop, allowing rapid tuning and experiment-informed updates to a flight-like test matrix. The EDU dynamic environment was characterized with accelerometers, strain gauges, and high-frequency pressure transducers all sampled at 20 kHz. While many narrow-band oscillations were identified, no significant FIV occurred; the reactor structural responses tend to be enveloped by typical launch vehicle ascent vibration environments (defined up to 2 kHz), although significant energy is also present at higher frequencies.

Flow Induced Vibration↗

NASA NTRS2006

Progress on Shape Memory Alloy Actuator Development for Active Clearance Control

Results of a numerical analysis evaluating the feasibility of high-temperature shape memory alloys (HTSMA) for active clearance control actuation in the high-pressure turbine section of a modern turbofan engine has been conducted. The prototype actuator concept considered here consists of parallel HTSMA wires attached to the shroud that is located on the exterior of the turbine case. A transient model of an HTSMA actuator was used to evaluate active clearance control at various operating points in a test bed aircraft engine simulation. For the engine under consideration, each actuator must be designed to counteract loads from 380 to 2000 lbf and displace at least 0.033 in. Design results show that an actuator comprised of 10 wires 2 in. in length is adequate for control at critical engine operating points and still exhibit acceptable failsafe operability and cycle life. A proportional-integral- derivative (PID) controller with integrator windup protection was implemented to control clearance amidst engine transients during a normal mission. Simulation results show that the control system exhibits minimal variability in clearance control performance across the operating envelope. The final actuator design is sufficiently small to fit within the limited space outside the high-pressure turbine case and is shown to consume only small amounts of bleed air to adequately regulate temperature.

Jonathan DeCastro↗

NASA NTRSDate not supplied

Physics-Guided Deep Learning for Complex System Health Management and Decision Making

The landscape of complex engineered systems is rapidly evolving, from smart manufacturing facilities to next-generation transportation vehicles. As these systems become increasingly sophisticated and interconnected, the need for advanced health management systems grows ever more critical. These systems must go beyond simple monitoring, actively predicting potential failures before they occur. This paradigm shift from fixed maintenance schedules to condition-based predictions is key to optimizing system performance, enhancing safety, and paving the way for autonomous decision-making across various industries. Whether in industrial processes, energy systems, or advanced transportation, the ability to anticipate and prevent failures is becoming a cornerstone of operational excellence. To accurately predict the future health of any complex system, knowledge of its current health state and future operational conditions is essential. Recent advancements in data-driven algorithms have generated growing interest in artificial intelligence for industrial applications. However, the limitations of pure data-driven methods, particularly in industries where data acquisition is costly and limited, have become apparent. This has led to a focus on blending physics with data-driven algorithms, mitigating the drawbacks of both approaches while emphasizing their respective advantages. This research proposes a novel framework for integrating physics-based performance models with deep learning algorithms for the prognostics of complex safety-critical systems. In this approach, physics-based models serve as a blueprint, capturing fundamental system behaviors, while deep learning algorithms, leveraging real-world sensor data, fill in gaps and identify subtle patterns indicative of potential problems. This hybrid methodology, utilizing techniques such as Physics-Informed Neural Networks (PINNs), offers a powerful solution for predicting system health. By fusing domain knowledge with data-driven insights, this approach promises more accurate, adaptable, and reliable models for health prediction. The resulting framework is versatile, applicable across various sectors including aerospace, manufacturing, and energy systems, ultimately contributing to safer, more efficient operations in our increasingly complex technological landscape.

Diagnostics↗

NASA NTRSDate not supplied

Development and Validation of a High-Vacuum Thermal Conductivity Testbed for Aerospace Interface Materials

Spacecraft thermal margins depend on the temperature penalty of installed interfaces, yet catalog conductivity omits bondline thickness, mating surfaces, preload, and environment. The Testbed for Advanced Interface Materials in Vacuum (TAIMV) addresses this engineering-data gap by converting ambient/vacuum temperature fields from a four-coupon stack into quantities usable in spacecraft thermal models. Its 17-node steady-state model resolves axial conduction, parasitic fixture paths, grease-filled contact, radiation, and ambient convection. Four monolithic checks gave axial heat-rate ratios of 0.90–1.02, and Braycote calibration self-recovery gave 2.20% casewise mean absolute percentage error (MAPE) and 2.85% maximum difference. With transferable fixture terms frozen, Krytox LVP tested cross-material transfer against a manufacturer-derived external relation. The six Krytox cases gave 2.28% MAPE, 5.10% maximum difference, and full-field residual root-mean-square values of 0.553 °C ambient and 1.306 °C vacuum. Installed-joint resistance spanned 6.39–7.15 × 10⁻⁴ m²·K/W for Braycote and 4.09–4.49 × 10⁻⁴ m²·K/W for Krytox, corresponding to 2.33–6.66 K per modeled interface over the tested heat-flux range. TAIMV therefore supplies directly usable installed-joint resistance and conductance, plus apparent installed conductivity and explicitly model-conditioned grease conductivity/contact terms.

heat transfer↗

NASA NTRS2026

Development and Experimental Validation of a Path-Dependent Spin Forming Finite Element Model

Spin forming is an advanced manufacturing process widely used in the aerospace and defense sectors to produce lightweight, high-strength cylindrical components with tight dimensional tolerances. This study explores the applicability of the path-dependent Mechanical Threshold Stress (MTS) constitutive model by simulating the evolution of geometry, machining forces, and plastic deformation during the spin forming of a 10-mm thick 6061-O aluminum cylinder. While numerical modeling of spin forming has advanced substantially over the past decade, systematic verification and experimental validation of material models remain limited, particularly in predicting through-thickness process evolution. The MTS model, incorporating a Voce hardening rule, is employed for its ability to represent cyclic loading, rapidly varying temperature fields, and strain rates characteristic of spin forming. Numerical convergence analysis indicates discretization uncertainties between 0.3% and 9.2% for key quantities of interest. Experimental validation demonstrates that the MTS model, when implemented with a verified mesh, accurately reproduces both elastic and plastic behavior of 6061-O aluminum, predicting peak roller loads within 11–18% of measurements, geometric tolerances within 3%, and plastic strain distributions within 10% of experimental values. Collectively, these results establish a validated computational framework for predictive spin-forming simulations with quantified confidence, providing a foundation for extension to other alloys, geometries, and forming conditions.

Spin forming↗

NASA NTRS2026

PROTECT: Production and Reuse of Thermally Efficient Ceramic Thermal Protection Systems

PROTECT (Production and Reuse Of Thermally Efficient Ceramic TPS) is a NASA Early Career Initiative focused on developing the next generation of reusable ceramic thermal protection systems (TPS). This project addresses key challenges in TPS design, including temperature capability, thermal stability, and refurbishment time, by integrating novel material development with predictive modeling. Leveraging enhanced capabilities in NASA’s Porous Microstructure Analysis (PuMA) software, PROTECT introduces new modeling tools to predict the thermal and mechanical behavior of fibrous ceramic materials. These tools enable accurate prediction of performance metrics such as thermal conductivity and structural integrity, reducing reliance on costly physical testing. Preliminary advances in these areas will be presented. To support model validation, PROTECT is building a comprehensive database of raw material properties using advanced characterization techniques, including micro computed tomography (CT) scanning in collaboration with the University of Illinois Urbana-Champaign (UIUC). The presentation will detail the sampling workflows and analysis methods used to generate this detailed microstructural data and how it is used to develop improved models in PuMA. This multi-center collaboration, spanning NASA (JSC, ARC, KSC, GRC), Oak Ridge National Laboratory, UIUC, and SpaceX, is developing tailored TPS solutions for LEO, lunar, and Martian missions. By bridging heritage systems with the demands of modern spaceflight, PROTECT contributes to the advancement of reusable TPS technologies for future exploration missions.

Propulsion, Refractory, and Coating Materials↗

NASA NTRS2026

Development, Characterization, and Validation of Elevated-Temperature Constitutive Models: Deformation and Damage

This report provides a brief review of experimentally observed hereditary and nonhereditary material behavior along with background information on standard as well as advanced internal state variable constitutive modeling at elevated temperature. A description of exploratory, characterization, and validation testing is presented along with a detailed outline of what constitutes “sufficient” data content (i.e., quality and quantity) for developing or enhancing, characterizing, and validating a particular sophisticated nonlinear time- and history-dependent (hereditary) class of constitutive models known as GVIPS (generalized viscoplasticity with potential structure). The tests described are necessary to reveal a material’s behavior in the reversible (or viscoelastic) and irreversible (or viscoplastic) regimes, for the identification of both deformation and damage model parameters. Results presented are primarily for metallic materials. In all cases, both uniaxial and multiaxial tests are described, and the linkage between the specific tests and the parameters within the model that can be characterized from the results of these tests are also discussed. Discussion is also provided relative to the role information management must play relative to material data collection, analysis, maintenance, and dissemination. The need for such an information system is particularly important as both analyst and designer move toward utilizations of sophisticated, nonlinear time- and history dependent (hereditary) constitutive models. Lastly, the concept of state space and its utility in understanding and establishing constitutive models is addressed throughout. The intent behind this document is to help both the modeler and experimentalist understand each other’s specific points of view and provide guidance for both model development and characterization. Emphasis has been placed on providing the mechanician with information regarding how tests are performed and what issues to be aware of when interpreting results. It is hoped that experimentalists will take away a new perspective on the types of information that modelers and analysts are looking for from them.

Constitutive Modeling↗

NASA NTRS2026

Assessment of Aircraft Electric Engine Regulatory Special Conditions

This report provides a regulatory gap assessment of the Federal Aviation Administration (FAA) and the European Union Aviation Safety Agency (EASA) Special Conditions (SC) for electric engines. This information is presented to support ongoing international harmonization efforts for electric engine certification, to establish a level of safety consistent across regulatory bodies and equivalent to that of existing combustion engines. HS Advanced Concepts LLC assembled a team of subject-matter experts to develop a comprehensive comparison of the regulatory text of EASA SC E-19 and the FAA special conditions for the certification of electric engines. The team included Mr. Chris Baczynski of BAC Aerospace Inc. and Mr. Zach Kaufman, formerly with magniX.

aircraft certification↗

NASA NTRS2026

PROTECT: Production and Reuse of Thermally Efficient Ceramic Thermal Protection Systems

PROTECT (Production and Reuse Of Thermally Efficient Ceramic TPS) is a NASA Early Career Initiative focused on developing the next generation of reusable ceramic thermal protection systems (TPS). This project addresses key challenges in TPS design, including temperature capability, thermal stability, and refurbishment time, by integrating novel material development with predictive modeling. Leveraging enhanced capabilities in NASA’s Porous Microstructure Analysis (PuMA) software, PROTECT introduces new modeling tools to predict the thermal and mechanical behavior of fibrous ceramic materials. These tools enable accurate prediction of performance metrics such as thermal conductivity and structural integrity, reducing reliance on costly physical testing. Preliminary advances in these areas will be presented. To support model validation, PROTECT is building a comprehensive database of raw material properties using advanced characterization techniques, including micro computed tomography (CT) scanning in collaboration with the University of Illinois Urbana-Champaign (UIUC). The presentation will detail the sampling workflows and analysis methods used to generate this detailed microstructural data and how it is used to develop improved models in PuMA. This multi-center collaboration, spanning NASA (JSC, ARC, KSC, GRC), Oak Ridge National Laboratory, UIUC, and SpaceX, is developing tailored TPS solutions for LEO, lunar, and Martian missions. By bridging heritage systems with the demands of modern spaceflight, PROTECT contributes to the advancement of reusable TPS technologies for future exploration missions.

Propulsion, Refractory, and Coating Materials↗