Canopy wins Air Force contracts to develop thermal protection systems

The U.S. Air Force awarded Canopy Aerospace two contracts with a combined value of $2.8 million to develop thermal protection systems (TPS). One contract focuses on Canopy’s transpiration-cooled TBS. Under a second contract, Canopy will embed high-temperature sensors in the TPS material. Denver-based Canopy was founded in 2021 to develop manufacturing processes that rely on software, automation and 3D-printing to supply heat shields for spacecraft and hypersonic vehicles. “We’ve since expanded our vision significantly to solve thermal management across all industries including space, defense, power generation, power electronics and computer systems,” Matt Shieh, Canopy co-founder and CEO, told SpaceNews. Canopy’s latest contracts were awarded in August through AFWERX in partnership with the Air Force Research Laboratory Space Vehicles Directorate’s Atomic Long-Range Systems Branch. The Air Force Materiel Command’s Arnold Engineering Development Complex is supporting the work. The Air Force contracts “help inform and influence our work with commercial partners,” Shieh said. “We see the government as validating the technology that needs to be developed and the problems that need to be solved in this industry.”

Canopy's high-heat flux testing of thermal protection system materials. Credit: Canopy Aerospace

Transpiration Cooling

Canopy is additively manufacturing ceramic materials for transpiration-cooled TPS under one of the contracts. Hypersonic vehicles can cool themselves by expelling pressurized fluid from the leading edge. The evaporating fluid forms an insulation layer, protecting the vehicle from extreme heating during atmospheric reentry.

Under a second award, Canopy is embedding sensors in the TPS to monitor the environment. The goal is to “extend the design envelope for future systems development and reduce downtime needed for maintenance and inspection of strategic nuclear reentry systems,” according to the Sept. 5 news release.

While the research campaigns are distinct, the technologies – transpiration-cooling and embedded sensors – could be combined in future TPS designs, Will Dickson, Canopy chief commercial officer, said by email.

Canopy is holding a ribbon-cutting ceremony Sept. 5 for its new facility south of Denver. The 6,096-square-meter facility is designed for the company’s manufacturing and materials development activities.

To date, Canopy has won $7.5 million in government contracts and raised $4 million in venture capital.