Hung D. Nguyen and Gynelle C. Steele

Glenn Research Center, Cleveland, Ohio

An Overview of SBIR Phase 2 Materials Structures

for Extreme Environments

NASA/TM—2015-218858

August 2015
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Hung D. Nguyen and Gynelle C. Steele

Glenn Research Center, Cleveland, Ohio

An Overview of SBIR Phase 2 Materials Structures

for Extreme Environments

NASA/TM—2015-218858

August 2015

National Aeronautics and

Space Administration

Glenn Research Center

Cleveland, Ohio 44135
Available from

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Space Administration.

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This report is available in electronic form at http://www.sti.nasa.gov/ and http://ntrs.nasa.gov/
Abstract 

Technological innovation is the overall focus of NASA’s Small Business Innovation Research 

(SBIR) program. The program invests in the development of innovative concepts and 

technologies to help NASA’s mission directorates address critical research and development 

needs for agency projects. 

This report highlights innovative SBIR Phase II projects from 2007-2012 specifically addressing 

Areas in Materials and Structures for Extreme Environments which is one of six core 

competencies at NASA Glenn Research Center. There are twenty three technologies featured

with emphasis on a wide spectrum of applications such as fine-filament superconductor wire, 

composite oxide cathode materials, nano-composites, high radiation solar cell, wrapped 

multilayer insulation, thin aerogel, and much more. Each article in this booklet describes an 

innovation, technical objective, and highlights NASA commercial and industrial applications.

This report serves as an opportunity for NASA personnel including engineers, researchers, and 

program managers to learn of NASA SBIR’s capabilities that might be crosscutting into this 

technology area. As the result, it would cause collaborations and partnerships between the small 

companies and NASA Programs and Projects resulting in benefit to both SBIR companies and 

NASA. 

An Overview of SBIR Phase 2 Materials Structures 

for Extreme Environments 

Hung D. Nguyen and Gynelle C. Steele 

National Aeronautics and Space Administration 

Glenn Research Center 

Cleveland, Ohio 44135 

NASA/TM—2015-218858 1
NASA 

} Space launch systems

} Composite cryotanks 

} In-space structures

Commercial

} Private space launch vehicles

} Oil and gas consumables

} Aircraft

} Large marine vessels

} Civil and automotive 

infrastructure

} Wind blades and towers

No-Oven, No-Autoclave 

Composite Processing 

Rapid fabrication of large, single-piece composite structures

Very large composite structures, such as those used in NASA’s Space Launch 

System, push the boundaries imposed by current autoclaves. New technology is 

needed to maintain composite performance and free manufacturing engineers 

from the restraints of curing equipment size limitations.

Recent efforts on a Phase II project by Cornerstone Research Group, Inc. 

(CRG), have advanced the technology and manufacturing readiness levels of a 

unique two-part epoxy resin system. Designed for room-temperature infusion 

of a dry carbon preform, the system includes a no-heat-added cure that delivers 

350 °F composite performance in a matter of hours. This no-oven, no-autoclave 

(NONA) composite processing eliminates part-size constraints imposed by 

infrastructure and lowers costs by increasing throughput and reducing capitalspecific, process-flow bottlenecks. As a result of the Phase II activity, NONA 

materials and processes were used to make high-temperature composite tooling 

suitable for further production of carbon-epoxy laminates and honeycomb/

sandwich-structure composites with an aluminum core.

The technology platform involves tooling design, resin infusion processing, 

composite part design, and resin chemistry. The various technology elements are 

combined to achieve a fully cured part. The individual elements are not unusual, 

but they are combined in such a way that enables proper management of the 

heat generated by the epoxy resin during cure. The result is a self-cured carbon/

epoxy composite part that is mechanically and chemically stable at temperatures 

up to 350 °F. As a result of the successful SBIR effort, CRG has launched 

NONA Composites as a spinoff subsidiary. The company sells resin to end users, 

fabricates finished goods for customers, and sells composite tooling made with 

NONA materials and processes to composite manufacturers. 

Firm Contact

Cornerstone Research Group, Inc.

Michael D. Rauscher

rauschermd@crgrp.com

2750 Indian Ripple Road

Dayton, OH 45440–3638

Phone: 937–320–1877 ext. 1266

Proposal Number: 10-2 X5.03-9924

Applications

Phase II Objectives

} Improve resin processability

} Scale up honeycomb core and 

sandwich structure fabrication

} Validate NONA as a composite tooling 

system

} Improve manufacturing readiness

} Plan for technology transition 

Benefits

} Eliminates capital-specific process 

bottlenecks

} Enables single-piece fabrication of 

large composite structures

} Reduces time in tooling acquisition as 

well as part fabrication

} Provides high performance in an epoxy 

at temperatures up to 350 °F 

} Allows for on-site manufacturing

} Simplifies fabrication logistics

} Reduces labor time and cost

} Increases composite part throughput

} Eliminates post-cure requirement

CRG photos

NASA/TM—2015-218858 2
3

NASA 

} Launch vehicle structures

} Large composite structures

} Composite cryotanks

Commercial

} Military and commercial aircraft

} High-performance composite 

applications 

} Large structures

Out-of-Autoclave Cure Composites 

Technology provides excellent balance of mechanical 

properties and damage tolerance

As the size of aerospace composite parts exceeds that of even the largest 

autoclaves, the development of new out-of-autoclave processes and materials is 

necessary to ensure quality and performance. Many out-of-autoclave prepreg 

systems can produce high-quality composites initially; however, due to long 

layup times, the resin advancement commonly causes high void content and 

variations in fiber volume. 

Applied Poleramic, Inc. (API), developed an aerospace-grade benzoxazine matrix 

composite prepreg material that offers more than a year out-time at ambient 

conditions and provides exceptionally low void content when out-of-autoclave 

cured. When compared with aerospace epoxy prepreg systems, API’s innovation 

offers significant improvements in terms of out-time at ambient temperature 

and the corresponding tack retention. The carbon fiber composites developed 

with the optimized matrix technology have significantly better mechanical 

performance in terms of hot-wet retention and compression when compared 

with aerospace epoxy matrices. These composites also offer an excellent overall 

balance of properties. This matrix system imparts very low cure shrinkage, low 

coefficient of thermal expansion, and low density when compared with most 

aerospace epoxy prepreg materials.

Firm Contact

Applied Poleramic, Inc.

Brian S. Hayes

hayesb1@sbcglobal.net

6166 Egret Court

Benicia, CA 94510–1269

Phone: 707–707–6738

Proposal Number: 09-2 X5.03-9388

Applications

Phase II Objectives

} Develop matrices with out-ofautoclave processing characteristics

} Develop carbon fiber unidirectional 

prepreg systems using the novel 

matrices

} Demonstrate high-quality, low-void 

content, single vacuum bag ovencured composites

} Demonstrate long out-times 

and insensitivity to the layup 

environment

} Demonstrate aerospace mechanical 

performance 

Benefits

} Long out-time

} Low sensitivity to layup environment

} High modulus 

} Damage tolerant

Applied Poleramic, Inc., photo

NASA/TM—2015-218858 3
NASA 

} Stator coils for all-electric aircraft

} Generators

} Motors

} Transformers

} Inductors

} Power conditioning equipment

} Magnetic bearings

} Actuators

} Magnetohydrodynamic magnets 

} Propulsion engines

} Magnetic shielding in space

} Magnetic launch devices

Commercial

} Rotor coils for motors and 

generators

} Background magnets for 

magnetic resonance imaging 

(MRI) devices

} Inductive-type superconducting 

fault current limiters

} Resistive fault current limiters

} Low-speed direct-drive wind 

turbine generators

} Stators for generators and motors 

(50–400 Hz)

} Transformers

} Reactors

} Inductors

Fine-Filament MgB2

Superconductor Wire 

For turboelectric aircraft propulsion systems and numerous 

commercial uses 

Hyper Tech Research, Inc., has developed fine-filament magnesium diboride 

(MgB2

) superconductor wire for motors and generators used in turboelectric 

aircraft propulsion systems. In Phase I of the project, Hyper Tech demonstrated 

that MgB2

 multifilament wires (<10 micrometers) could reduce alternating 

current (AC) losses that occur due to hysteresis, eddy currents, and coupling 

losses. The company refined a manufacturing method that incorporates a 

magnesium-infiltration process and provides a tenfold enhancement in critical 

current density over wire made by a conventional method involving magnesiumboron powder mixtures. Hyper Tech also improved its wire-drawing capability 

to fabricate fine multifilament strands. 

In Phase II, the company developed, manufactured, and tested the wire for 

superconductor and engineering current density and AC losses. Hyper Tech also 

fabricated MgB2

 rotor coil packs for a superconducting generator. The ultimate 

goal is to enable low-cost, round, lightweight, low-AC-loss superconductors 

for motor and generator stator coils operating at 25 K in next-generation 

turboelectric aircraft propulsion systems.

Firm Contact

Hyper Tech Research, Inc.

Sherrie Cantu

hypertechresearch@gmail.com

539 Industrial Mile Road

Columbus, OH 43228–2412

Phone: 740–517–1938

Proposal Number: 12-2 A3.03-9094

Applications

Phase II Objectives

} Develop high-filament-count, singlerestack MgB2

 superconductors

} Optimize the double-restack conductor

} Reduce the twist pitch and develop 

MgB2

 conductors with a reduced 

number of magnetic components

} Develop MgB2 superconductors with 

reduced transport current losses and 

different versions of MgB2

 cables

} Develop low-AC-loss secondgeneration MgB2

 superconductor wire

} Characterize the superconductivity and 

AC losses of MgB2

 wire, cables, and 

racetrack coils

} Deliver low-AC-loss MgB2 wire to 

NASA and other collaborators

} Outline a follow-on Phase III program 

Benefits

} Low cost

} Lightweight 

} Low density

} Configurable in any critical current 

as a round wire

} Low AC loss

Superconducting Motors Driving Fans

Hyper Tech Research, Inc. illustration

Fine filament 

(10 μm goal)

Enhancement in critical 

current density

Long piece-length

(potentially 60 km)

Superconducting Generator

Turboshaft Engine

NASA/TM—2015-218858 4
NASA 

} Wide operating temperature 

power semiconductors for space 

power systems and science 

missions:

•	 Spacecraft orbiting Earth, 

Venus, Europa, and Titan

•	 Lunar Quest Program 

Commercial 

} Power electronics, along with 

computer and microprocessor 

technology:

•	 Automobiles, electric 

utilities, pollution controls, 

communications, computer 

systems, consumer electronics, 

and factory automation

} Hybrid electric vehicles

} Renewable energy conversion

} Power supplies

High-Temperature, Wirebondless, 

Ultracompact Wide Bandgap Power 

Semiconductor Modules 

For space and commercial power systems

Silicon carbide (SiC) and other wide bandgap semiconductors offer great 

promise of high power rating, high operating temperature, simple thermal 

management, and ultrahigh power density for both space and commercial 

power electronic systems. However, this great potential is seriously limited by 

the lack of reliable high-temperature device packaging technology. 

This Phase II project developed an ultracompact hybrid power module 

packaging technology based on the use of double lead frames and direct 

lead frame-to-chip transient liquid phase (TLP) bonding that allows device 

operation up to 450 °C. The new power module will have a very small form 

factor with 3–5X reduction in size and weight from the prior art, and it will 

be capable of operating from 450 °C to –125 °C. This technology will have a 

profound impact on power electronics and energy conversion technologies and 

help to conserve energy and the environment as well as reduce the 

nation’s dependence on fossil fuels.

Firm Contact

Advanced Power Electronics Corp. (ApECOR) 

John Elmes

jelmes@apecor.com

3259 Progress Drive, Suite A

Orlando, FL 32826–2930

Phone: 407–275–1174

Proposal Number: 09-2 S3.05-8550

Applications

Phase II Objective

} Develop an ultracompact hybrid 

power module packaging technology 

based on the use of double lead 

frames and direct lead frame-to-chip 

TLP bonding

Benefits

} Device operation up to 450 °C

} Very high current-carrying capability

} Low package parasitic impedance

} Low thermomechanical stress at high 

temperatures

} Double-side cooling

} Modularity for easy system-level 

integration

NASA photo

NASA/TM—2015-218858 5
NASA 

} Lunar landers 

} Extravehicular activities 

} Lunar surface systems

} Rovers

Commercial

} Hybrid electric vehicles

} Consumer electronics:

•	 Laptops

•	 Mobile phones

•	 Cameras

•	 Camcorders

•	 Portable televisions and radios

•	 Power tools

} Medical devices

} Electric bicycles and scooters

} Military vehicles

High-Capacity, High-Voltage 

Composite Oxide Cathode Materials 

For use in lithium-ion batteries 

This SBIR project integrates theoretical and experimental work to enable 

a new generation of high-capacity, high-voltage cathode materials that will 

lead to high-performance, robust energy storage systems. At low operating 

temperatures, commercially available electrode materials for lithium-ion (Li-ion) 

batteries do not meet energy and power requirements for NASA’s planned 

exploration activities. NEI Corporation, in partnership with the University 

of California, San Diego, has developed layered composite cathode materials 

that increase power and energy densities at temperatures as low as 0 °C and 

considerably reduce the overall volume and weight of battery packs. 

In Phase I of the project, through innovations in the structure and morphology 

of composite electrode particles, the partners successfully demonstrated an 

energy density exceeding 1,000 Wh/kg at 4 V at room temperature. In Phase II, 

the team enhanced the kinetics of Li-ion transport and electronic conductivity 

at 0 °C. An important feature of the composite cathode is that it has at least 

two components that are structurally integrated. The layered material is 

electrochemically inactive; however, upon structural integration with a spinel 

material, the layered material can be electrochemically activated and deliver a 

large amount of energy with stable cycling. 

Firm Contact

NEI Corporation

Nader M. Hagh

nmhagh@neicorporation.com

400 Apgar Drive, Suite E

Somerset, NJ 08873–1154

Phone: 732–868–3141

Proposal Number: 08-2 T3.01-9909

Applications

Phase II Objective

} Enhance the kinetics of Li-ion 

transport and electronic conductivity 

at 0 °C in composite electrode 

materials

Benefits

} Maintains high energy and power 

densities at low temperatures

} Improves battery efficiency

} Stabilizes and enhances battery cell 

safety

NASA/TM—2015-218858 6
NASA 

} Crew and launch vehicles

} Portable power for landers, 

rovers, and astronaut equipment

} Storage systems for crew 

exploration and spacecraft

} Stationary energy storage systems

Commercial

} Hybrid electric vehicles

} Consumer electronic devices

Silicon Whisker and Carbon 

Nanofiber Composite Anode 

For spacecraft, electric vehicles, and bulk 

energy storage units

Silicon is an attractive anode material for lithium-ion (Li-ion) batteries because 

of its theoretical high-charge capacity; however, silicon anodes have limited 

applications because silicon’s volume changes by 300 percent upon insertion and 

extraction of lithium, which results in capacity fading. 

Physical Sciences Inc., has developed a silicon whisker and carbon nanofiber 

composite anode for use in Li-ion batteries that provides capacity greater than 

1,000 mAh/g for more than 200 cycles (at 100 percent depth of discharge). 

The innovation’s unique silicon architecture and structural reinforcement (made 

possible by the nanofibers) combine to provide a synergistic improvement in 

reversible capacity and electrochemical cycling. In addition, the developed 

powder can be handled and processed into electrodes using established 

procedures and equipment. The resulting battery system has the capability 

to provide an energy density of greater than 220 Wh/kg. A scalable synthesis 

process enables low-cost incorporation into electric vehicles and bulk energy 

storage units. 

Firm Contact

Physical Sciences Inc.

Christopher M. Lang

lang@psicorp.com

20 New England Business Center

Andover, MA 01810–1077

Phone: 978–689–0003

Proposal Number: 08-2 X6.02-9113

Applications

Phase II Objectives

} Demonstrate production levels of 

grams per batch

} Achieve full cell anode capacity of 

>1,000 mAh/g at a charge rate of 

10 (C/10) and 0 °C

} Establish a full cell cycle life of over 

300 cycles

} Display an operating temperature of 

–30 °C to +30 °C

} Demonstrate a rate capability of C/5 

or higher

} Deliver to NASA three 2.5 Ah cells 

(energy density >220 Wh/kg)

} Exhibit the safety features of the 

anode and full cells

} Design a 1 kWh prismatic battery 

pack 

Benefits

} High capacity

} High power

} Improved cycle life

} Low cost

Physical Sciences Inc. illustration

NASA/TM—2015-218858 7
NASA 

} Power for landers, rovers, and 

extravehicular activities (EVAs)

} Space-related applications in 

Moon and other planetary 

habitats 

Commercial 

The new anodes will result in highperformance Li-ion batteries suitable 

for the following 

commercial applications: 

} Electric vehicle propulsion

} Portable consumer products:

•	 Cellular phones

•	 Portable power tools

•	 Cameras

•	 Laptop computers

Mesoporous Silicon-Based Anodes 

For high-capacity, high-performance lithium-ion batteries

A new high-capacity anode composite based on mesoporous silicon is being 

developed. With a structure that resembles a pseudo one-dimensional phase, 

the active anode material will accommodate significant volume changes 

expected upon alloying and dealloying with lithium (Li). The mesoporosity is 

created without the aid of a surfactant template using a novel, high-volume 

synthetic process. The anode composite based on this material is designed 

to have a reversible Li-ion capacity exceeding 600 mAh/g—or nearly twice 

that obtainable with graphite anodes—and much higher capacities could 

be attainable. Phase I successfully demonstrated the synthesis of this new 

meso-silicon (Si) material as well as its high electrochemical activity and 

rechargeability. Phase II expanded the investigation of the development of 

mesoporous Si-based Li-ion anodes. The optimum anode was evaluated in 

Li-ion cells containing 4-V oxide cathodes.

Firm Contact

EIC Laboratories, Inc.

Dharmasena Peramunage

pera@eiclabs.com

111 Downey Street

Norwood, MA 02062–2612

Phone: 781–769–9450

Proposal Number: 09-2 X7.01-8568

Applications

Phase II Objectives

} Expand the investigation of the 

development of a mesoporous, 

Si-based Li-ion anode 

} Evaluate the optimum anode in Li-ion 

cells containing 4-V oxide cathodes

Benefits

} Reversible Li-ion capacity exceeding 

600 mAh/g (nearly twice that 

obtainable with graphite anodes)

} Nonflammable

} Subambient temperature operation

NASA/TM—2015-218858 8
NASA 

} Ascent module of the Altair 

Lunar Lander 

} Lunar extravehicular activity 

(EVA) suit and integrated 

portable life support systems

} Lunar surface systems and 

mobility systems 

} Uninterruptable power systems 

(UPS) for Orion spacecraft, the 

International Space Station (ISS), 

and other spaceflight vehicles

Commercial and Military

} Power sources for hybrid 

electric and electric vehicles 

(HEV and EV)

} Portable consumer electronics

} Handheld military equipment, 

exploration robots, and drones

SiLix-C Nanocomposites 

For high energy density Li-ion battery anodes

For this Phase II project, Superior Graphite Co., in collaboration with the 

Georgia Institute of Technology and Streamline Nanotechnologies, Inc., 

developed, explored the properties of, and demonstrated the enhanced 

capabilities of novel nanostructured SiLix-C anodes. These anodes can retain 

high capacity at a rapid 2-hour discharge rate and at 0 °C when used in Li-ion 

batteries. 

In Phase I, these advanced anode materials had specific capacity in excess of 

1,000 mAh/g, minimal irreversible capacity losses, and stable performance 

for 20 cycles at C/1. The goals in Phase II were to develop and apply a variety 

of novel nanomaterials, fine-tune the properties of composite particles at the 

nanoscale, optimize the composition of the anodes, and select appropriate 

binder and electrolytes. In order to achieve a breakthrough in power 

characteristics of Li-ion batteries, the team developed new nanostructured 

SiLix-C anode materials to offer up to 1,200 mAh/g at C/2 at 0 °C.

Firm Contact

Superior Graphite Co.

Francois Henry

FHenry@superiorgraphite.com

10 South Riverside Plaza, Suite 1470

Chicago, IL 60606–3700

Phone: 773–209–4793

Proposal Number: 08-2 X6.02-8492

Applications

Phase II Objectives

} Identify ideal combination of binder 

and electrolyte material to maximize 

performance for silicon-carbon (SiC) 

nanocomposite powder at 0 °C using 

a charge/discharge rate of C/2

} Identify and adjust optimum parameters 

of SiC nanocomposite powder, such as 

particle size, thickness, and morphology 

of the carbon coating; porosity of the 

adaptive carbon matrix; size of Si 

crystals; and Si content

} Determine origin of irreversible 

capacity loss 

} Plan and build small pilot plant 

} Optimize synthesis process of SiC 

nanocomposite powders to maximize 

uniformity and reproducibility

} Develop an anode-based on the novel 

SiC nanocomposite powder that offers 

1,200 mAh/g at C/2 at 0 °C and a 

long cycle life

Benefits

} High energy density

} Dramatically improved capacity

} Cycling performance

NASA illustration

NASA/TM—2015-218858 9
NASA 

} Multijunction germanium 

(Ge)-based solar cells

} Inverted metamorphic solar cells 

with more than four junctions

} Next-generation solar cells

} Solar cells in unmanned aerial 

vehicle (UAV) platforms

Commercial

} Multijunction Ge-based 

solar cells

} Inverted metamorphic solar cells 

with more than four junctions

} Next-generation solar cells

} Solar cells in UAV platforms

} Power generation for military 

field deployments and 

supplementary mobile devices

Advanced Antireflection Coatings 

for High-Performance Solar Energy 

Applications 

Integrated technologies significantly increase efficiency

Antireflection coatings are a critical element of high-performance photovoltaic 

(PV) devices, as they are responsible for coupling light from the cover glass 

into the top layer of the solar cell. MicroLink Devices, Inc. has explored several 

techniques to improve antireflection coatings for both triple- and quadruplejunction solar cells to enhance cell efficiency. 

In Phase II, MicroLink developed multilayer dielectric antireflection coatings 

that incorporated lanthanum titanate (LaTiO3

) films to achieve significantly 

improved optical coupling between the cover glass and cell at the ultraviolet 

and infrared ends of the spectral range of interest. The company also refined 

a fabrication process to oxidize the aluminum (Al)-containing window layer, 

reducing light absorption at the short end of the spectral range of interest and 

providing extra usable photons to the cell. These integrated innovations increase 

the light coupling between the cover glass and cell, achieving high-performance 

efficiency in next-generation PV devices containing four or more junctions. 

These new coatings are expected to increase relative efficiency by at least 

7 percent and absolute efficiency by 2.5 percent.

Firm Contact

MicroLink Devices, Inc.

Noren Pan

npan@mldevices.com

6457 Howard Street

Niles, IL 60714–3301

Phone: 847–588–3001 

Proposal Number: 12-2 S3.02-9667

Applications

Phase II Objectives

} Develop and refine antireflection 

coatings incorporating LaTiO3

 as an 

intermediate refractive index material

} Investigate wet/dry thermal oxidation 

of Al-containing semiconductor 

compounds as a means of forming a 

more transparent window layer with 

equal or better optical properties than 

its unoxidized form

} Develop a fabrication process that 

allows integration of the oxidized 

window layer and maintains the 

necessary electrical properties for 

contacting the solar cell

} Conduct an experimental 

demonstration of the best candidates 

for improved antireflection coatings 

Benefits

} Enables a new generation of 

lightweight, high-efficiency solar cells 

and panels

} Increases the efficiency of solar arrays 

used in NASA space applications

} Increases the availability of electrical 

power to satellites

} Improves solar cell performance in 

UAVs 

MicroLink Devices, Inc. illust.

NASA/TM—2015-218858 10
NASA 

} Deep space vehicles

} Electronic and radioisotope 

propulsion

} Ion thruster technologies

} Lightweight thermal interface 

materials

Commercial

} Tactical quiet generators

} Hybrid electric vehicle drive 

systems

} High-power light-emitting diode 

(LED) luminaries

} Wind power converters

} Electricity transportation and 

distribution systems

} Marine vessel propulsion

CarbAlTM Heat Transfer Material 

Thermal management for space flight systems

The increasing use of power electronics, such as high-current semiconductor 

devices and modules, within space vehicles is driving the need to develop 

specialty thermal management materials in both the packaging of these 

discrete devices and the packaging of modules consisting of these device arrays. 

Developed by Applied Nanotech, Inc. (ANI), CarbAl heat transfer material 

is uniquely characterized by its low density, high thermal diffusivity, and high 

thermal conductivity. Its coefficient of thermal expansion (CTE) is similar to 

most power electronic materials, making it an effective base plate substrate for 

state-of-the-art silicon carbide (SiC) super junction transistors. 

The material currently is being used to optimize hybrid vehicle inverter 

packaging. Adapting CarbAl-based substrates to space applications was a 

major focus of the SBIR project work. In Phase I, ANI completed modeling 

and experimentation to validate its deployment in a space environment. 

Key parameters related to cryogenic temperature scaling of CTE, thermal 

conductivity, and mechanical strength. In Phase II, the company concentrated 

on improving heat sinks and thermally conductive circuit boards for power 

electronic applications.

Firm Contact

Applied Nanotech, Inc.

Richard Fink

dfink@appliednanotech.net

3006 Longhorn Boulevard, Suite 107

Austin, TX 78758–7631

Phone: 512–339–5020 ext. 130

Proposal Number: 12-2 S3.04-8357

Applications

Phase II Objectives

} Refine Phase I thermal model for 

CarbAl-based thermal packaging 

that encompasses specific thermal 

loads of SiC transistors targeted for 

use in space vehicles

} Fabricate heat sink system for direct 

current (DC) power conversion 

module

} Demonstrate bench performance 

temperature reductions of 8 percent 

from 160 K to 300 K

} Complete prototype CarbAl heat 

sink system

} Target flight deployment testing for 

2015

Benefits

} Fewer thermal interfaces

} Lower mass-density ratio

} Matched CTE

} Improved thermal resistance

ANI photo

Direct-Print Conductive Trace

CarbAITM Substrate

Polymeric Dieletric

ANI’s CarbAITM 

Thermal 

Base Plate

NASA/TM—2015-218858 11
NASA 

} Nozzle extensions for upper- and 

exoatmospheric operation:

•	 Robotic lunar and planetary 

missions

•	 Manned lunar ascent

•	 J-2X rocket systems

} TPS for next-generation 

spacecraft

Commercial

} Lower-cost, high-performance 

nozzle extensions for commercial 

launch market 

} TPS for reusable aircraft that 

operate in temperatures in excess 

of 2,800 °F (a safe operating 

temperature for repeated use)

High-Melt Carbon-Carbon Coating 

for Nozzle Extensions 

Ultrahigh-temperature ceramics enable novel material

Carbon-Carbon Advanced Technologies, Inc. (C-CAT), has developed a 

high-melt coating for use in nozzle extensions in next-generation spacecraft. 

The coating is composed primarily of carbon-carbon, a carbon-fiber and 

carbon-matrix composite material that has gained a spaceworthy reputation due 

to its ability to withstand ultrahigh temperatures. C-CAT’s high-melt coating 

embeds hafnium carbide (HfC) and zirconium diboride (ZrB2

) within the 

outer layers of a carbon-carbon structure. The coating demonstrated enhanced 

high-temperature durability and suffered no erosion during a test in NASA’s Arc 

Jet Complex. (Test parameters: stagnation heat flux=198 BTD/ft2

-sec; 

pressure= .265 atm; temperature=3,100 °F; four cycles totaling 28 minutes)

In Phase I of the project, C-CAT successfully demonstrated large-scale 

manufacturability with a 40-inch cylinder representing the end of a nozzle 

extension and a 16-inch flanged cylinder representing the attach flange of a 

nozzle extension. These demonstrators were manufactured without spalling or 

delaminations. In Phase II, C-CAT worked with engine designers to develop 

a nozzle extension stub skirt interfaced with an Aerojet Rocketdyne RL10 

engine. All objectives for Phase II were successfully met. Additional nonengine 

applications for the coating include thermal protection systems (TPS) for 

next-generation spacecraft and hypersonic aircraft. 

Firm Contact

Carbon-Carbon Advanced Technologies, Inc.

James Thompson

jthompson@c-cat.net

4704 Eden Road

Kennedale, TX 76060–6800

Phone: 817–985–2500

Proposal Number: 09-2 X10.01-8831

Applications

Phase II Objectives

} Verify that prototype nozzle 

extension designs are 

manufacturable and meet technique 

requirements

} Design and fabricate layup tools 

that address ply shrinkage distortion 

yet maintain dimensional tolerances 

during processing

} Lay up the nozzle extensions 

without defects

} Process each nozzle extension 

through pyrolysis, heat treatment, 

and coating without defects

} Apply silicon carbide conversion 

coating to the high-melt material 

without spalling

Benefits

} Lighter weight than conventional 

metallic structures

} Able to operate in temperatures in 

excess of 2,800 °F repeatedly and 

at higher temperatures for one-time 

use 

} Easy to manufacture

C-CAT photos

NASA/TM—2015-218858 12
NASA 

} Aerospace systems that require 

minimal or no maintenance over 

extended periods of time:

•	 Rovers

•	 Machinery used to construct 

lunar habitats

Commercial

} Industrial transportation systems

} Construction vehicles

} Military vehicles and equipment

} Gyroscope bearings on satellites

High-Performing, 

Low-Temperature-Operating, 

Long-Lifetime Aerospace 

Lubricants 

For use in aerospace and terrestrial applications

Long-duration space exploration will require spacecraft systems that can operate 

effectively over several years with minimal or no maintenance. Aerospace 

lubricants are key components of spacecraft systems. Physical Sciences Inc., has 

synthesized and characterized novel ionic liquids for use in aerospace lubricants 

that contribute to decreased viscosity, friction, and wear in aerospace systems. 

The resulting formulations offer low vapor pressure and outgassing properties 

and thermal stability up to 250 °C. They are effective for use at temperatures as 

low as –70 °C and provide long-term operational stability in aerospace systems. 

In Phase II, the company scaled several new ionic liquids and evaluated a novel 

formulation in a NASA testbed. 

The resulting lubricant compounds will offer lower volatility, decreased 

corrosion, and better tribological characteristics than standard liquid lubricants, 

particularly at lower temperatures.

Firm Contact

Physical Sciences Inc.

Prakash Joshi

joshi@psicorp.com

20 New England Business Center

Andover, MA 01810–1077

Phone: 978–689–0003

Proposal Number: 08-2 X4.01-9712

Applications

Phase II Objectives

} Synthesize and characterize 12 

novel (>98 percent purity) ionic 

liquids

} Establish vapor pressures 

<10–7 Torr at 25 °C and stability up 

to 250 °C

} Demonstrate a reduction in 

corrosion and a 20 percent viscosity 

decrease from –70 °C to +60 °C

} Demonstrate a lower coefficient 

of friction (COF) and a reduction 

of wear effects of lubricant 

formulations

} Scale four ionic liquids to 25 grams 

each

} Achieve a lower COF and reduced 

wear and volatility in a NASA 

testbed 

Benefits

} Low volatility

} Chemically stable

} Excellent tribological characteristics 

at low temperatures

NASA photo

NASA/TM—2015-218858 13
NASA 

} Propulsion systems

} In-space science missions

} Lunar and planetary exploration 

activities

} Satellites

Commercial

} Launch systems

} Missiles

} Ballistic defense systems

} Satellites

Nontoxic Ionic Liquid Fuels 

for Exploration Applications 

For safer, less expensive propulsion systems

The toxicity of propellants used in conventional propulsion systems increases 

not only safety risks to personnel but also costs, due to special handling required 

during the entire lifetime of the propellants. Orbital Technologies Corporation 

(ORBITEC) has developed and tested novel nontoxic ionic liquid fuels for 

propulsion applications. In Phase I of the project, the company demonstrated 

the feasibility of several ionic liquid formulations that equaled the performance 

of conventional rocket propellant monomethylhydrazine (MMH) and also 

provided low volatility and low toxicity. 

In Phase II, ORBITEC refined the formulations, conducted material property 

tests, and investigated combustion behavior in droplet and microreactor 

experiments. The company also explored the effect of injector design on 

performance and demonstrated the fuels in a small-scale thruster. The ultimate 

goal is to replace propellants such as MMH with fuels that are simultaneously 

high-performance and nontoxic. The fuels will have uses in NASA’s propulsion 

applications and also in a range of military and commercial functions.

Firm Contact

Orbital Technologies Corporation

Millicent Coil

coilm@orbitec.com

1212 Fourier Drive

Madison, WI 53717–1961

Phone: 608–229–2812

Proposal Number: 09-2 X10.01-9473

Applications

Phase II Objectives

} Synthesize ionic liquid fuels that 

ignite hypergolically with nitrogen 

tetroxide

} Characterize ignition and 

combustion through drop and 

microreactor tests

} Measure the material properties of 

the candidate fuels

} Determine the molecular structures 

via nuclear magnetic resonance 

spectroscopy

} Predict performance and analyze 

integration into propulsion systems

} Scale up synthesis

} Investigate the effects of the injector 

design on ignition and combustion

} Determine the influence of chamber 

size on combustion efficiency

} Conduct ignition tests and small 

rocket test firings to demonstrate 

performance

Benefits

} Increased performance

} Reduced toxicity

} Reduced cost

} Increased safety

NASA photo

NASA/TM—2015-218858 14
NASA 

} Engine and airframe 

components:

•	 Actuators

•	 Flexible wings

•	 Nozzles

•	 Ballistic impact–resistant 

structures

Commercial

} Structural building and bridge 

components that resist explosions 

and earthquakes

} Armor

} Automobile spoilers

} Shipboard structures

} Biomedical implants

} Firefighting equipment

} Heating, ventilation, and 

air conditioning (HVAC) 

equipment

} Sporting goods

Periodic Cellular Structure 

Technology for Shape Memory 

Alloys 

Unique approach offers low-cost fabrication method

Shape memory alloys are being considered for a wide variety of adaptive 

components for engine and airframe applications because they can undergo 

large amounts of strain and then revert to their original shape upon heating 

or unloading. Transition45 Technologies, Inc., has developed an innovative 

periodic cellular structure (PCS) technology for shape memory alloys that 

enables fabrication of complex bulk configurations, such as lattice block 

structures. These innovative structures are manufactured using an advanced 

reactive metal casting technology that offers a relatively low cost and established 

approach for constructing near–net shape aerospace components. Transition45 

is continuing to characterize these structures to determine how best to design 

a PCS to better exploit the use of shape memory alloys in aerospace applications.

Firm Contact

Transition45 Technologies, Inc.

Edward Y. Chen

transition45@sbcglobal.net

1963 North Main Street

Orange, CA 92865–4101

Phone: 714–283–2118

Proposal Number: 09-2 A2.01-8248

Applications

Phase II Objectives

} Design, exploit, and maximize the 

performance benefits of cast shape 

memory alloys in the form of PCSs 

and solids

} Examine how well PCSs of various 

designs perform in recovery 

compared with a solid of the 

same alloy

} Quantify structural benefits of 

PCS technology

Benefits

} Lightweight

} Acoustic dampening

} Impact resistant

} Flexible

} Strong

Flexible-wing F/A-18 

(NASA photo)

Transition45 

Technologies, Inc.

inset photo

NASA/TM—2015-218858 15
NASA 

} Rotorcraft systems

Commercial

This technology could be applied 

to gears across many consumer 

industries, including: 

} Aviation

} Industrial 

} Automotive

Braided Composite Technologies 

for Rotorcraft Structures 

To reduce weight, noise, and vibration 

A&P Technology has developed a braided material approach for fabricating 

lightweight, high-strength hybrid gears for aerospace drive systems. The 

conventional metallic web was replaced with a composite element made from 

A&P’s quasi-isotropic braid. The 0°, +/–60° braid architecture was chosen 

so that inplane stiffness properties and strength would be nearly equal in all 

directions. 

The test results from the Phase I Small Spur Gear program demonstrated 

satisfactory endurance and strength while providing a 20 percent weight 

savings. (Greater weight savings is anticipated with structural optimization.) 

The hybrid gears were subjected to a proof-of-concept test of 1 billion cycles 

in a gearbox at 10,000 revolutions per minute and 490 in-lb torque with no 

detectable damage to the gears. After this test the maximum torque capability 

was also tested, and the static strength capability of the gears was 7x the 

maximum operating condition. Additional proof-of-concept tests are in 

progress using a higher oil temperature, and a loss-of-oil test is planned. 

 

The success of Phase I led to a Phase II program to develop, fabricate, and 

optimize full-scale gears, specifically Bull Gears. The design of these Bull 

Gears will be refined using topology optimization, and the full-scale Bull 

Gears will be tested in a full-scale gear rig. The testing will quantify benefits 

of weight savings, as well as noise and vibration reduction. The expectation 

is that vibration and noise will be reduced through the introduction of 

composite material in the vibration transmission path between the contacting 

gear teeth and the shaft-and-bearing system.

Firm Contact

A&P Technology

Nathan Jessie

4595 East Tech Drive

Cincinnati, OH 45245–1055

Phone: 513–688–3200

Fax: 513–688–3201

Proposal Number: 11-2: A2.09-8194

Phase II Objectives

} Determine operating conditions for 

a gear in a rotorcraft gearbox

} Develop, fabricate, and optimize 

full-scale composite/metal hybrid 

gears for full-scale validation testing

} Evolve analytical tools to enable 

design optimization

Benefits

} Decreased weight in rotorcraft 

gearboxes

} Reduced noise and vibration

Applications

Accelerometers

Driver gear

Loaded gear

A&P Technology photos

NASA/TM—2015-218858 16
NASA 

} Medium Earth orbit missions

} Outer planet missions

} Satellite power systems

Commercial

} Concentrator photovoltaic 

(CPV) systems to provide 

terrestrial solar power

High Radiation Resistance 

IMM Solar Cell 

For efficient, lightweight, radiation-resistant solar power

Due to high launch costs, weight reduction is a key driver for the development 

of new solar cell technologies suitable for space applications. This project is 

developing a unique triple-junction inverted metamorphic multijunction 

(IMM) technology that enables the manufacture of very lightweight, low-cost 

InGaAsP-based multijunction solar cells. This IMM technology consists 

of indium (In) and phosphorous (P) solar cell active materials, which are 

designed to improve the radiation-resistant properties of the triple-junction 

solar cell while maintaining high efficiency. The intrinsic radiation hardness of 

InP materials makes them of great interest for building solar cells suitable for 

deployment in harsh radiation environments, such as medium Earth orbit and 

missions to the outer planets. NASA Glenn’s recently developed epitaxial lift-off 

(ELO) process also will be applied to this new structure, which will enable the 

fabrication of the IMM structure without the substrate. 

Firm Contact

MicroLink Devices, Inc.

Noren Pan

npan@mldevices.com

6457 West Howard Street

Niles, IL 60714–3301

Phone: 847–588–3001 ext. 13

Proposal Number: 09-2 S3.03-8143

Phase II Objectives

} Reduce efficiency degradation to 

less than 10 percent

} Develop solar cells with efficiency 

greater than 30 percent

} Maintain high end-of-life 

performance 

Benefits

} Suitable for harsh environments

} Reduces or eliminates the heavy 

cover glass materials as required 

on conventional gallium-arsenide 

(GaAs)-based cells

} Uses the quaternary InGaAsP 

subcell rather than the GaAs 

subcell, allowing the use of a set 

of bandgaps that better match the 

solar spectrum

} Reuses multiple times, and 

ultimately recycles, the GaAs 

substrate on which the solar cell is 

grown via the ELO process 

Applications

NASA photo

NASA/TM—2015-218858 17
NASA 

} Near- to medium-term NASA 

Discovery, Flagship OuterPlanets, and New Frontiers–class 

science missions

} Interplanetary comet rendezvous 

and solar electric propulsion 

science missions

} Low Earth orbit (LEO), 

geosynchronous Earth orbit 

(GEO), planetary or celestialbody lander, planetary orbiter, 

and/or deep space applications

Commercial and Military

} Power and energy production for 

fixed-ground, mobile, and roofmounted consumer applications

} High-altitude airship applications 

} LEO surveillance, 

reconnaissance, communications, 

commercial mapping, and other 

critical payload/equipment 

satellites

} GEO commercial and Defense 

Department communications 

and critical payload/equipment 

satellites

Lightweight IMM PV Flexible 

Blanket Assembly 

For high-voltage solar electric propulsion missions

Deployable Space Systems (DSS) has developed an inverted metamorphic 

multijunction (IMM) photovoltaic (PV) integrated modular blanket assembly 

(IMBA) that can be rolled or z-folded. This IMM PV IMBA technology 

enables a revolutionary flexible PV blanket assembly that provides high specific 

power, exceptional stowed packaging efficiency, and high-voltage operation 

capability. DSS’s technology also accommodates standard third-generation 

triple junction (ZTJ) PV device technologies to provide significantly improved 

performance over the current state of the art. 

This SBIR project demonstrated prototype, flight-like IMM PV IMBA panel 

assemblies specifically developed, designed, and optimized for NASA’s highvoltage solar array missions.

Firm Contact

Deployable Space Systems

Brian Spence

Brian.Spence@DeployableSpaceSystems.com

75 Robin Hill Road, Building B2

Goleta, CA 93117–3108

Phone: 805–805–1313

Proposal Number: 09-2 S3.03-8863

Phase II Objectives

} Demonstrate and validate 

prototype IMM PV IMBA panel 

assemblies specifically developed, 

designed, and optimized for 

NASA’s high-voltage solar array 

missions

} Develop scalable analytical models 

and correlate with test results to 

validate IMM PV IMBA prototype 

hardware

} Develop technology and 

manufacture infrastructure 

Benefits

} High-voltage operability

} High specific power 

(>1,000 W/kg beginning of life 

[BOL] at the blanket subsystem 

level; >500 W/kg BOL at the array 

level)

} Compact stowage volume 

(>50 kW/m3

)

} Rollable or z-foldable for stowage

} Flexible and durable

} Adaptable to all existing industry 

flexible blanket solar array 

products

Applications

NASA photo

NASA/TM—2015-218858 18
NASA 

} Missions near the Sun:

•	 Solar Orbiter

•	 Solar Sentinels in the Living 

with a Star (LWS) Program 

} Missions in high-radiation 

environments

Commercial and Military

} Terrestrial DoD applications

InGaN High-Temperature 

Photovoltaic Cells 

For high-temperature, high-radiation environments

This Phase II project developed Indium-Gallium-Nitride (InGaN) photovoltaic 

cells for high-temperature and high-radiation environments. The project 

included theoretical and experimental refinement of device structures produced 

in Phase I as well as modeling and optimization of solar cell device processing. 

The devices have been tested under concentrated air mass zero (AM0) sunlight, 

at temperatures from 100 °C to 250 °C, and after exposure to ionizing 

radiation. The results are expected to further verify that InGaN can be used for 

high-temperature and high-radiation solar cells. 

The large commercial solar cell market could benefit from the hybridization 

of InGaN materials to existing solar cell technology, which would significantly 

increase cell efficiency without relying on highly toxic compounds. In addition, 

further development of this technology to even lower bandgap materials for 

space applications would extend lifetimes of satellite solar cell arrays due to 

increased radiation hardness. This could be of importance to the Department 

of Defense (DoD) and commercial satellite manufacturers.

Firm Contact

Integrated Micro Sensors, Inc. 

David Starikov 

dstarikov@imsensors.com

10814 Atwell Drive

Houston, TX 77096–4934

Phone: 713–748–7926

Proposal Number: 08-2 S3.03-9731

Applications

Phase II Objectives

} Refine single-junction device 

structures

} Optimize the processing of 

single-junction devices

} Demonstrate two-junction devices

} Verify the stability of InGaN solar 

cells at high temperatures and high 

radiation environments

Benefits

} Remains stable in high-temperature 

and high-radiation environments

} Extends lifetime of satellite solar cell 

arrays

NASA/TM—2015-218858 19
NASA 

} Solar electric propulsion 

programs

Commercial and Military

} Electric-powered unmanned 

aerial vehicles (UAVs)

} Commercial and military 

satellites

} Portable solar electric power 

chargers

High-Volume Production of 

Lightweight Multijunction 

Solar Cells 

Reduces the cost of cells via a 6-inch gallium arsenide 

(GaAs) epitaxial lift-off and substrate reclaim process

MicroLink Devices, Inc., has transitioned its 6-inch epitaxial lift-off (ELO) 

solar cell fabrication process into a manufacturing platform capable of 

sustaining large-volume production. This Phase II project improves the ELO 

process by reducing cycle time and increasing the yield of large-area devices. 

In addition, all critical device fabrication processes have transitioned to 

6-inch production tool sets designed for volume production. An emphasis 

on automated cassette-to-cassette and batch processes minimizes operator 

dependence and cell performance variability. MicroLink Devices established 

a pilot production line capable of at least 1,500 6-inch wafers per month 

at greater than 80 percent yield. The company also increased the yield and 

manufacturability of the 6-inch reclaim process, which is crucial to reducing 

the cost of the cells.

Firm Contact

MicroLink Devices, Inc.

Christopher Youtsey

cyoutsey@mldevices.com

6457 West Howard Street

Niles, IL 60714–3301

Phone: 847–588–3001

Proposal Number: 11-2 X8.04-9001 

Phase II Objectives

} Improve the manufacturability 

and reduce the cost of the 6-inch 

ELO process for fabricating highefficiency, large-area 

multijunction solar cells 

} Optimize the 6-inch ELO process 

for high throughput and yield 

(greater than 80 percent)

} Use automated process tool sets 

capable of more than 1,500 6-inch 

wafers per month

} Establish a production-ready 

6-inch GaAs substrate reclaim 

process

Benefits

} Produces lightweight and high 

specific power multijunction solar 

cells

} Offers an inexpensive and 

streamlined manufacturing process 

Applications

MicroLink Devices, Inc., photo

NASA/TM—2015-218858 20
NASA 

} Solar electric propulsion:

•	 Appropriate for NASA 

missions that require highefficiency photovoltaic 

power production 

through deployment of an 

ultralightweight and highly 

modular structural system

Commercial

} Solar electric propulsion

} Low Earth orbit (LEO) 

surveillance, reconnaissance, 

communications, commercial 

mapping, and other critical 

payload/equipment satellites

} Medium Earth orbit (MEO) 

satellites and space tugs

} Geosynchronous orbit (GEO) 

communications and critical 

payload/equipment satellites

} Fixed-ground and deployable/

retractable mobile ground-based 

systems

Optimization of the Roll-Out Solar 

Array (ROSA) and Mega-ROSA 

High-efficiency photovoltaic power production

The Mega-ROSA is a new, highly modularized, and extremely scalable selfdeployed solar array that provides immense power level range capability, 

from 100 kilowatts to several megawatts. Mega-ROSA, an enhancement of 

NASA’s ROSA, will enable extremely high power spacecraft and solar electric 

propulsion powered missions, including space tug and large-scale planetary 

science and lunar/asteroid exploration missions. Mega-ROSA/ROSA is 

adaptable to all photovoltaic and concentrator flexible blanket technologies.

This Phase II project optimized the Mega-ROSA/ROSA technology and 

deployable structural system. More specifically, the project optimized the 

elastically deployable slit-tube thin-shell boom structures through advanced 

composites design, development and analytical modeling, materials design 

and development, innovative and affordable manufacturing processes, and 

the development of accurate engineering methodologies to rapidly allow for 

new material properties and design performance characterizations. The team 

developed new and innovative structural sections/configurations, such as 

section closeout and root reinforcement. Finally, the team developed and 

refined innovative and affordable composite structure fabrication processes.

Firm Contact

Deployable Space Systems, Inc.

Brian Spence

Brian.Spence@DeployableSpaceSystems.com

75 Robin Hill Road, Building B2

Goleta, CA 93117–3108

Phone: 805–722–8090

Proposal Number: 11-2 T3.01-9785

Phase II Objectives

} Optimize Mega-ROSA/ROSA solar 

array materials and structures

} Characterize creep/relaxation 

phenomena 

} Perform analytical modeling

} Optimize the array’s manufacturing 

process

Benefits

} Inexpensive

} Ultralightweight

} Compact stowage volume 

(< 50 kW/m3

 for very large arrays)

} High strength and stiffness

} Capable of providing power levels 

from 60 kW to more than 300 kW

} Operates in high-voltage and highor low-temperature environments

} Radiation tolerant

} Scalable

Applications

NASA photo NASA photo NASA photo

NASA/TM—2015-218858 21
NASA 

} Solar electric propulsion (SEP)

} Electric and magnetic field 

instruments used on NASA 

science spacecraft:

•	 Time History of Events and 

Macroscale Interactions 

during Substorms (THEMIS)

•	 Magnetospheric Multiscale 

(MMS) mission

•	 Mars Atmosphere and Volatile 

Evolution (MAVEN) space 

probe

•	 Direct-drive SEP approaches

Commercial 

} Commercial spacecraft 

Thin, Flexible IMM Solar Array 

Offering higher efficiencies and lower mass and flexibility

NASA needs solar arrays that are thin, flexible, and highly efficient; package 

compactly for launch; and deploy into large, structurally stable high-power 

generators. Inverted metamorphic multijunction (IMM) solar cells can enable 

these arrays, but integration of this thin crystalline cell technology presents 

certain challenges. The Thin Hybrid Interconnected Solar Array (THINS) 

technology allows robust and reliable integration of IMM cells into a flexible 

blanket comprising standardized modules engineered for easy production. The 

modules support the IMM cell by using multifunctional materials for structural 

stability, shielding, coefficient of thermal expansion (CTE) stress relief, and 

integrated thermal and electrical functions. The design approach includes total 

encapsulation, which benefits high voltage as well as electrostatic performance. 

In Phase I of this project, the THINS design was refined for enhanced 

environmental durability and integration into a large deployment structure 

such as Mega Roll-Out Solar Array (Mega-ROSA) or MegaFlex. Phase II 

advanced the THINS technology, incorporating advanced IMM solar cells 

into THINS modules and then integrating these modules into the MegaFlex 

deployable structure where it underwent environmental testing, including 

launch vibration, thermal vacuum deployment, and electrostatic discharge/

plasma testing. The THINS technology is further enhanced by automated 

manufacturing activities being performed under a Phase II SBIR with NASA, 

focusing on reducing manufacturing costs and scale-up. This technology is 

expected to provide tens to hundreds of kilowatts to enable outer planetary 

missions, allow improved solar electric propulsion performance during cruise, 

and provide significant power (i.e., hundreds of watts) despite the minimal 

sunlight available at the asteroid belt, Jupiter, and beyond.

Firm Contact

Vanguard Space Technologies, Inc.

Nicholas Walmsley

nwalmsley@vst-inc.com

9431 Dowdy Drive

San Diego, CA 92126–4633

Phone: 858–587–4200 ext. 1849

Proposal Number: 10-2 X8.04-9431

Applications

Phase II Objectives

} Fabricate and performance test a 

full-scale module

} Test module coupons in the 

most stressing simulated space 

environments

} Develop and fabricate a deployment 

demonstration of a THINS MegaFlex 

array containing a complete 

photovoltaic array blanket comprising 

THINS modules with some active cells

} Demonstrate full-scale deployment at 

ambient, hot, and cold temperatures

Benefits

} Designed for manufacturability using 

mature semiconductor industry 

standard equipment and processes

} Fits tens of kilowatts in a compact 

stowage envelope

} Improves process control

} Enables smaller, more economical 

launch vehicles

} Uses total encapsulation and 

continuity of cover glass materials 

to create a continuous grounded, 

shielded enclosure

NASA illustration

NASA/TM—2015-218858 22
NASA 

} New NASA vehicles

} Orbiting fuel depots

} Vacuum-insulated pipe used to 

transfer cryogens

Commercial 

} Food, research, medical, and 

industrial applications:

•	 Transfers of cryogenic liquid 

into and from cryogenic 

dewars for liquid nitrogen 

(LN2

), hydrogen (LHe), and 

oxygen (LOX)

} Industrial:

•	 Handling LN2

, LOX, and 

liquefied natural gas (LNG)

•	 Handling piping, automatic 

filling equipment, dewar 

manifolds, and gas panels

} LNG:

•	 High-performance insulated 

cryogenic transfer piping 

to reduce LNG losses from 

vaporization during liquid 

transfer

} LN2 equipment:

•	 Semiconductor, electronics, 

and aerospace environmental 

temperature testing

•	 Special effects (fogging), 

biological freezing 

applications, inerting of food 

and beverage containers, 

container pressurization, and 

food freezing

Wrapped Multilayer Insulation 

Thermal insulation for cryogenic piping

New NASA vehicles, such as Earth Departure Stage (EDS), Orion, landers, and 

orbiting fuel depots, need improved cryogenic propellant transfer and storage 

for long-duration missions. Current cryogen feed line multilayer insulation 

(MLI) performance is 10 times worse per area than tank MLI insulation. 

During each launch, cryogenic piping loses approximately 150,000 gallons 

(equivalent to $300,000) in boil-off during transfer, chill down, and ground 

hold. Quest Product Development Corp., teaming with Ball Aerospace, 

developed an innovative advanced insulation system, Wrapped MLI (wMLI), 

to provide improved thermal insulation for cryogenic feed lines.

wMLI is high-performance multilayer insulation designed for cryogenic piping. 

It uses Quest’s innovative discrete-spacer technology to control layer spacing/

density and reduce heat leak. The Phase I project successfully designed, built, 

and tested a wMLI prototype with a measured heat leak 3.6X lower than 

spiral-wrapped conventional MLI widely used for piping insulation. A wMLI 

prototype had a heat leak of 7.3 W/m2

, or 27 percent of the heat leak of 

conventional MLI (26.7 W/m2

). 

The Phase II project is further developing wMLI technology with custom, 

molded polymer spacers and advancing the product toward commercialization 

via a rigorous testing program, including developing advanced vacuuminsulated pipe for ground support equipment.

Firm Contact

Quest Product Development Corporation 

Scott A. Dye

sdye@quest-corp.com

6833 Joyce Street

Arvada, CO 80007–7570

Phone: 303–670–5088 ext. 12

Proposal Number: 09-2 X8.01-8258

Applications

Phase II Objectives

} Design and develop a custom, 

molded polymer spacer

} Further develop assembly and 

installation processes

} Develop and test wMLI for three 

different piping diameters

} Conduct testing to optimize spacer 

and wrap geometries

} Perform thermal testing on 12 

different wMLI test configurations

} Perform thermal testing on 

advanced ”clam-shell” netting MLI

} Design, develop, and test MLI in a 

vacuum-insulated pipe prototype for 

use in ground support equipment

Benefits

} Low heat leak (3.6X less than 

conventional MLI)

} Easy assembly

} Few layers

} Low cost

} Less mass

NASA/TM—2015-218858 23
NASA 

} Insulation for cryotanks and 

cryogen transfer pipelines for 

ground processing 

} Cryogen storage insulation for 

in-space applications

} Satellite thermal management

} Extravehicular activity (EVA) 

suits 

} Internal insulation on future 

generations of reusable launch 

vehicles

Commercial

} Durable and reliable insulation 

systems for any cryogenic, highvacuum, or thin and 

flexible applications: 

•	 Appliances

•	 Airliner fuselage

•	 Liquid natural gas fuel storage 

tanks and transfer lines

•	 Apparel

Thin Aerogel as a Spacer in 

Multilayer Insulation 

For cryogenic space applications

Cryogenic fluid management is a critical technical area that is needed for future 

space exploration. A key challenge is the storability of liquid hydrogen (LH2

), 

liquid methane (LCH4

), and liquid oxygen (LOX) propellants for long-duration 

missions. The storage tanks must be well-insulated to prevent overpressurization 

and venting, which can lead to unacceptable propellant losses for long-duration 

missions to Mars and beyond. 

Aspen Aerogels had validated the key process step to enable the fabrication 

of thin, low-density aerogel materials. The multilayer aerogel insulation 

(MLAI) system prototypes were prepared using sheets of aerogel materials with 

superior thermal performance exceeding current state-of-the-art insulation for 

space applications. The exceptional properties of this system include a new 

breakthrough in high-vacuum cryogenic thermal insulation, providing a durable 

material with excellent thermal performance at a reduced cost when compared 

to longstanding state-of-the-art multilayer insulation systems. During the Phase 

II project, further refinement and qualification/system-level testing of the MLAI 

system will be performed for use in cryogenic storage applications.

Aspen has been in discussions with United Launch Alliance, LLC; NASA’s 

Kennedy Space Center; and Yetispace, Inc., to test the MLAI system on realworld tanks such as Vibro-Acoustic Test Article (VATA) or the Cryogenic Orbital 

Testbed (CRYOTE).

Firm Contact

Aspen Aerogels 

Nancy Moroz

contracts@aerogel.com

30 Forbes Road, Building B

Northborough, MA 01532–2501

Phone: 508–691–1161

Proposal Number: 11-2 X10.01-9295

Applications

Phase II Objectives

} Refine low-density and thin aerogel 

formulations

} Optimize thin aerogel scale-up 

process and MLAI system fabrication

} Assess MLAI prototype performance:

•	 Cryostat 500 (size 8-in diameter) 

testing

} Large-scale testing of optimum 

MLAI system:

•	 Cryostat 100 (2 x 4-ft size)

•	 System-level testing at Ball 

Aerospace & Technologies Corp. 

Benefits

} More durable and robust multilayer 

insulation system that is easy to install

} Improved process for manufacturing 

thin, low-density aerogel materials

} Superior thermal insulation for 

cryogenic applications

Aspen Aerogels photo

NASA/TM—2015-218858 24