| Abstract Scope |
Conventional ablative thermal protection system (TPS) materials rely on Earth-manufactured precursors and high-temperature processing, limiting their suitability for off-world fabrication. Regolith, with its oxide-rich composition, low thermal conductivity, and high thermal stability, offers a promising in-situ resource for thermally insulating TPS materials. This work presents the design and additive manufacturing of the Regolith-Embedded Carbon Photopolymer Ablator (ReCPA), a functionally graded, ISRU-compatible ablator fabricated by incorporating regolith simulant and carbon additives into a UV-curable photopolymer matrix with spatially tailored compositions. UV curing enables rapid, low-energy processing compatible with portable manufacturing systems for extraterrestrial environments. Composite formulations with varying regolith and carbon loadings were systematically evaluated. High-temperature testing demonstrated stable ablation, robust char formation, and effective reduction of heat transfer to the underlying structure. ReCPA provides a lightweight, scalable, and manufacturable TPS concept for future lunar and Martian entry missions, where on-site fabrication and repair will be essential. |