Raven Space Systems develops test platforms for the US Air Force

Raven Space Systems has been awarded an STTR Phase II contract worth 1.8 million US dollars by AFWERX. The goal is to develop 3D-printed hypersonic flight test platforms specifically designed to meet the requirements of the U.S. Department of the Air Force. The contract is part of the Open Topic SBIR/STTR program, which has enabled small companies to develop and implement innovative technologies for the defense sector since 2018.

The research focuses on aeroshells, which are the protective layers of re-entry vehicles that are exposed to extreme thermal and mechanical stresses. Traditional manufacturing processes for these components are complex and cost-intensive. With the newly developed approach, Raven is relying on so-called Microwave Assisted Deposition (MAD) technology, a form of 3D printing that uses thermoset-based composite materials. This technology is intended to enable not only lighter but also more powerful structures, which are essential for hypersonic applications.

“Our selection for the STTR Phase II from AFWERX highlights the importance of Raven’s automated composite manufacturing technology for critical defense systems. This contract will allow Raven to develop our systems for reentry vehicle aeroshell production, including the thermal protection system that is traditionally difficult to manufacture. Raven’s breakthrough composite 3D printing innovation will significantly improve the efficiency of aeroshell production. Raven is excited to work with our partners on this project and honored to provide a unique hypersonics capability to the DoD.”, said Dr. Blake Herren, CEO of Raven Space Systems.

Collaboration with partners such as SpaceWorks Enterprises, Inc. and the University of Illinois Urbana-Champaign plays a central role in this project. Among other things, SpaceWorks provides RED Data systems for the re-entry technology, while the university provides access to state-of-the-art testing facilities for thermal protection materials.

“Since 2017, SpaceWorks has been at the forefront of reentry vehicle development, advancing solutions for both government and commercial hypersonic testing needs. With Raven’s cutting-edge 3D-printed aeroshell technology, we’re poised to drive down costs and expand capabilities, delivering affordable, high-performance hypersonic testing as a service to the industry.”, said Tyler Kunsa, VP of Defense & Space Systems at SpaceWorks.

“The University of Illinois is excited to support Raven and AFWERX in the pursuit of hypersonic flight. The Center for Hypersonics and Enty System Studies (CHESS) will deploy material science- grade testing for extreme materials to enable development and qualification of 3D printed flight testbeds, manufactured by Raven.”, said Dr. Francesco Panerai, Assistant Professor at UIUC.

With this project, Raven is playing a key role in the advancement of 3D printing technologies for the defense and aerospace industries by combining innovative materials and processes for hypersonic flight.