Numerical Methodology for the Conceptual Design of Conformal Ablative Heat Shields

Conformal ablators are low-density composite materials comprising a flexible fibrous substrate and polymer matrix. Recent advancements have improved the efficiency of conformal ablator fabrication through vacuum infusion processing, which injects resin into a fiber substrate enclosed in a matched mold under vacuum. A conceptual design methodology was developed combining a Darcy's law simulation of the mold filling process with optimal tile layout and material property estimation. The framework allows rapid evaluation of changes to constituent materials, process parameters, and heat-shield geometry, and their impact on manufacturing and material properties. Results for a 4.5 m, 70 deg sphere-cone aeroshell demonstrate the advantages of the integrated approach. The mold filling simulation is then compared with experimental results.