Agenda

High-Temperature Composite Solutions for Defense and Space Applications

Schedule: Thursday, October 16, 2025, 11:00 am-3:30 pm

*All times U.S. ET

11:00-11:15 am

Welcome, introduction

Scott Francis, editor-in-chief, CompositesWorld

11:15-11:45 am

Carbeon C/C-SiC: A Scalable, Cost-Effective Ceramic Matrix Composite for High-Temperature Applications

Rahul Shirke, founder and CEO, Arceon

Abstract: This presentation will discuss Arceon’s Carbeon C/C-SiC, an innovative ceramic matrix composite (CMC) that eliminates the need for fiber coatings, simplifying manufacturing and reducing costs. Utilizing uncoated carbon fiber reinforcement and no exotic or export controlled raw materials, this material offers exceptional thermal and mechanical performance, making it ideal for demanding defense and space applications. The optimized melt infiltration production process is not only faster but also scalable, enabling efficient production of components in various sizes and quantities to meet high demand. By reducing complexity and cost, Carbeon C/C-SiC provides an affordable alternative to traditional high temperature materials, facilitating broader adoption in high-temperature environments. This presentation will delve into the material's properties, melt infiltration process, manufacturing advantages, and potential applications (on-going projects), demonstrating how Carbeon C/C-SiC addresses the industry's need for high-performance, cost-effective, and scalable composite solutions.

11:45 am-12:15 pm

Novel Slurry Infusion for CMCs

Dr. Michael Welter, DLR/Fox Composites

Ceramic matrix composites (CMC) are widely considered one of the most promising materials for high-temperature applications. Particularly oxide CMC promise great potential for applications up to about 1400 °C due to easier manufacturing and lower cost compared to non-oxide CMC. However, their current use is mostly limited to niche markets. One of the main problems is the lack of robust and scalable fabrication technologies to enable a reproducible large-scale production of high-quality materials and components. For that purpose, we developed a novel slurry infusion technology (VASI® and IFOX®) at the German Aerospace Center (DLR). The materials and technology have already been proven in various DLR projects and flight missions focusssing primarily on defense and space applications such as radar transparent high temperature antenna covers, nose cones and reusable thermal protection systems. The technology is currently being scaled up and commercialization is planned through the DLR spin-off FOX Composites from early 2026.

12:15-1:00 pm

BREAK

1:00-1:30 pm

High Temperature Materials & Structures for Re-entry and Hypersonic Systems

Mario De Stefano Fumo, deputy head space materials and hot structures unit space directorate, CIRA

High-temperature materials remain one of the primary challenges in the development of space transportation and hypersonic systems. Ceramic Matrix Composites (CMCs) have emerged as a promising class of materials capable of meeting the demanding requirements of these applications.

Over the past decade, the Italian Aerospace Research Centre (CIRA), in collaboration with Petroceramics Spa, has developed ISiComp®, a Liquid Silicon Infiltration (LSI) carbon/silicon carbide (C/SiC) composite. ISiComp® offers a low-cost solution to produce thermal protection systems (TPS) and hot structures for space transportation vehicles.

This presentation will detail the development activities, design methodologies, manufacturing processes, and testing campaigns associated with the ceramic thermal protection systems employed on Space Rider, the reusable space transportation system funded by the European Space Agency (ESA).

In addition, a brief introduction to the emerging class of Ultra-High Temperature Ceramic Matrix Composites (UHTCMCs), capable of withstanding temperatures exceeding 2000°C, will be provided, highlighting their potential for future applications requiring extreme thermal resistance.

1:30-2:00 pm

Bridging the Thermal Performance and Cost Gap Between CFRPs and CMCs

Darren Friberg, VP Business Dev, Pyromeral Technology

Modern defense and space applications increasingly demand composite materials that exceed the thermal limits of CFRPs, yet often do not require the full capability of advanced CMCs. Many requirements involve sustained exposure to 1000°C with only short-duration excursions, creating a thermal performance and cost gap. This presentation introduces Pyromeral Technology’s family of geopolymer matrix composites that addresses this need, delivering lightweight, durable, easy-to-process solutions. Attendees will learn how these materials combine thermal  performance, design flexibility, and production efficiency. Topics include:

• Pyromeral’s proprietary ceramic matrix composites processed with a low-temperature autoclave cure and one freestanding post-cure
• Compatibility with conventional processes including hand lay-up, filament winding, and compression molding
• Elimination of densification/infiltration steps for reduced cost and lead time
• Complex shape capabilities on low-cost tooling
• Real-world applications in RF-transparent radomes, exhaust ducts, secondary structures, and heat shields

This session explores how Pyromeral’s geopolymer-based composites offer a new option in high-temperature aerospace design strategies.

2:00-2:30 pm

BREAK

2:30-3:00 pm

Phthalonitrile Composites for Carbon/Carbon and Ablative Thermal Protection

Joseph Severino, principal engineer- C/C, TPS, Cambium USA

Cambium-USA is leveraging machine learning and manufacturing experience to discover and bring to market new chemistries tailored for carbon/carbon and ablative thermal protection composites. This presentation will introduce Cambium’s unique phthalonitrile based resin, AS-1000. Phthalonitrile resins are advanced chemistries capable of high Tg over 400 °C and high char yield over 75 wt% but traditionally suffer from poor processability that has limited their application in aerospace and commercial applications. Following a brief introduction to phthalonitrile resin chemistry, details will be given into the processing of AS-1000 into densified carbon/carbon composites that dramatically reduce the required number of reinfiltration cycles necessary with heritage resin systems. Additionally, the processing and performance of this resin system for thermal ablation applications will be presented.

3:00-3:30 pm

Pyrolysis of Phenolic Resin and Other Organic Precursors for C-C and CMC Composites

William Carty, CTO, MRF Furnaces

The conversion of an organic precursor, such as phenolic resin or pitch, is a complex process step that is sensitive to temperature, heating cycle, furnace atmosphere (i.e., gas chemistry), and resin composition. As an example, based on a general approximation of phenolic resin chemistry, the carbon yield could theoretically be 90%, but actual yields in practice are typically around 50%. Most pyrolysis processes operate under an inert gas atmosphere, but our work has demonstrated that a small amount of oxygen, introduced in a controlled manner at low temperatures, can increase yield by up to 13%. This talk will focus on the pyrolysis process, the role of heating rate and gas chemistry, and other experiments designed to improve carbon yield.