Assessment of Additively Manufactured Thermoplastic Composites for Ablative Thermal Protection Systems (TPSs)

This study focused on the thermal stability and ablative behavior assessment of five newly developed composite TPS configurations. All ten test samples were 3D printed via FDM using various fire-retardant thermoplastic materials, with and without reinforcement. Eight samples integrated a new thermal management internal air chamber conceptualized architecture. A prompt feasible approach for the flame resistance preliminary assessment of ablative TPS samples was developed, using an in-house oxy-acetylene torch test bench. Experimental OTB ablation tests involved exposing the front surface samples to direct flame at 1450 ± 50 °C at 100 mm distance. For each configuration, two samples were tested: one subjected to 30 s of flame exposure and the other to 60 s. During testing, internal temperatures were measured at two backside sample contact points. Recorded temperatures remained below 46 °C, significantly under the maximum allowable back face temperature of 180 °C set for TPSs. The highest mass losses were measured for PC and PETG FR materials, achieving around 19% (30 s) and, respectively, 36% (60 s), while the reinforced configurations showed overall only a third of this reduction. The study’s major outcomes were the internal air chamber concept validation and identifying two reinforced configurations as strong candidates for the further development of 3D-printed ablative TPSs.