Canopy Awarded $2.8M Contract from USAF to Accelerate Commercialization of Next-Gen Thermal Protection Systems Technologies for Hypersonics and Re-entry Systems

FOR IMMEDIATE RELEASE

Canopy Awarded $2.8M Contract from USAF to Accelerate Commercialization of Next-Gen Thermal Protection Systems Technologies for Hypersonics and Re-entry Systems

Denver, CO – September 5, 2024 – Canopy Aerospace Inc. (Canopy), a leading innovator in specialized thermal protection systems (TPS), is proud to announce its latest initiative in partnership with the U.S. Air Force on $2.8M in contracts. This effort, which is part of a broader push by the Department of the Air Force (DAF) and the Department of Defense (DOD) to modernize its strategic weapons portfolio, addresses critical challenges in the development of advanced TPS for hypersonic vehicles and weapon systems. Founded in 2021, Canopy has proven its ability to apply new materials and manufacturing innovations in tandem to increase performance and reduce cost for high-temperature ceramic components such as TPS.

Hypersonic assets, capable of reaching speeds in excess of Mach 5, operate in some of the most extreme environments known to science, with temperatures reaching 3000°C. These conditions require assets such as weapons systems, space re-entry platforms, and transport aircraft to be engineered with dedicated TPS often constructed of a ceramic or ceramic-composite structure.

The supply base for these types of TPS materials dwindled after NASA’s sunsetting of the Space Shuttle program; with most materials developers recently having to focus on business survival instead of innovating. This has presented an opportunity for Canopy to kick off two development projects that will enable next-gen hypersonic and space re-entry systems to travel faster and more reliably than ever before.

Sweating to Keep Cool and Move Fast
‍The performance of any fast-moving system is limited by just how fast it can go – without degrading due to thermal stress. Canopy is developing a transpiration-cooled thermal protection system enabled by Canopy’s advances in additive manufacturing of ceramic materials. This innovative technology leverages the benefits of transpiration cooling to enhance the thermal resilience of TPS, enabling hypersonic systems to operate at higher speeds and perform more aggressive maneuvers.

Transpiration cooling works by expelling a highly-pressurized fluid from the leading edge of a hypersonic vehicle – instantly evaporating this fluid, which then forms a protective insulative layer for the vehicle that protects it from the extreme aerothermal heating generated from friction between the vehicle skin and the atmosphere.

“I think the biggest technological or industrial capability we can invest in would be to increase our production rates, particularly, of the thermal protection systems and additive – thermal protection systems for glide vehicles and additive manufacturing for cruise missile engines.” - Dr. Gillian Bussey, Director of the Joint Hypersonic Transition Office of the Under Secretary of Defense for Research & Engineering

Future weapon systems fielded by the USAF that leverage this innovation will be readily deployable for hypersonic applications, at scale. Of note, transpiration cooling is one of the only researched technologies that could enable true reusability for mass return from orbit on ballistic trajectories. By pursuing the development of transpiration-cooled TPS with integrated cooling channels, Canopy aims to push the boundaries of TPS technology, aligning with the DAF's strategic objectives and reinforcing the United States' leadership in hypersonic technology development.

Smart TPS for Health Monitoring and Data Capture
A second capability funded by these awards will be development of a proprietary, elevated temperature optical-fiber sensing capability for TPS that will extend the design envelope for future systems development and reduce downtime needed for maintenance and inspection of strategic nuclear re-entry systems: Health Monitoring Systems for Re-entry Systems (HMSRS or “Smart TPS”).

Space re-entry and hypersonic flight create a plasma layer surrounding the vehicle, which makes it exceedingly difficult for traditional sensors and communication protocols to function. By inserting sensors into the material used for TPS, future platforms will be able to ‘feel’ the environment around them at a much higher degree of precision – enabling new levels of understanding of materials ablation, along with the ability to monitor the structural health of the TPS throughout the vehicle’s lifespan.

This investment enables the appropriate level of engineering in manufacturability, ground testing, and integration trials to be flight-ready at the conclusion of the performance. This investment not only fills a gap in the hypersonic technologies field, but also serves the burgeoning ‘commercial low earth orbit’ economy being built by NASA and commercial space vehicle and re-entry bodies.

The combination of these technologies positions Canopy as a key partner in advancing the field of thermal protection systems, enabling both defense and space exploration systems to operate more effectively and efficiently in the harshest environments.

Strategic Alignment with U.S. Air Force Operational Imperatives
This innovative TPS solution aligns with the USAF’s "Global Strike" Operational Imperative, which focuses on developing resilient long-range strike capabilities against advanced threats. In an era of increasingly contested air, space, and cyber environments, the DAF must maintain its ability to hold any target at risk. The development of advanced TPS is crucial to the success of hypersonic systems, which are vital to the United States' strategic deterrence.

Canopy’s collaboration with the Air Force Research Laboratory Space Vehicles Directorate's Atomic Long Range Systems Branch (AFRL/RVBN) and Arnold Engineering Development Complex (AEDC) exemplifies the company's commitment to empowering the DAF with cutting-edge technologies.

Supporting the Defense Industrial Base
Canopy is dedicated to enhancing critical path technologies, reducing costs, and scaling high-rate production to meet the demands of modern defense needs. Canopy’s manufacturing capabilities directly support 8 of 14 Critical Technology Areas for National Security:

Advanced Computing, Advanced Materials, Directed Energy, Hypersonics, Microelectronics, Renewable Energy Generation and Storage, Quantum, and Space Technology.

“Getting U.S. Industrial base manufacturing right starts with top-down strategic guidance. We work closely with aligned U.S. Government agencies to execute and support the Office of the Under Secretary of Defense for Research and Engineering's (OUSD-R&E) critical technology areas in advanced materials.” – Matt Shieh, CEO/co-founder at Canopy

About Canopy
Canopy is a materials first, software-defined manufacturing company focused on solving the massive problem of thermal management for industries. The company is advancing overall industrial capacity of the most critical components to enable better performance of end-use systems. With a focus on low lead time, cost, and performance, Canopy is committed to supporting the Department of Defense and the broader defense industrial base in meeting the challenges of modern warfare, space exploration, and power systems.

For more information, please contact Canopy at info@canopyaerospace.com.