January 2025 - Physical Sciences Inc.

Press Release

Physical Sciences Inc. is leading the industry in research and development of advanced composites and its groundbreaking work in hypersonics was recently featured by the United States Advanced Ceramics Association (USACA).

“We want to be not only the lowest cost provider of silicon carbide composites,” George Rodgers, PSI’s Vice President for Advanced Composites, told the Advanced Ceramics Insights newsletter. “We also want to lead the industry in cycle time. We want to be the low-cost, rapid supplier of very high- performing [ceramic matrix composites].”

The association published an interview with Rodgers and John Steinbeck, a Principal Research Scientist, about the state of the composites industry and some of PSI’s cutting-edge work.

USACA: What do you think has changed the most in advanced ceramics?

John Steinbeck: For a very long time, ceramic composites went in and out of favor. For example, high-temperature ceramics would be hot in the DoD (Department of Defense), and then it would go away for other priorities.

A couple of things have changed that. The long-term investment made by General Electric to get the CMCs in their engine products has driven the private sector to push more because all the other large turbine manufacturers are afraid of being left behind. The second is the relatively sustained effort of the DoD to build hypersonic systems. These developments coincide with the ability to make materials that can withstand much higher temperatures and meet some of these unique defense applications.

USACA: Do you see growth areas beyond DoD?

John Steinbeck: We’ve also had a lot of interest from the rocket motor companies lately, including building nozzle extensions and a few other parts. The private rocket motor companies are coming to us, asking about CMCs because of the lighter weight and greater durability to accommodate the high-temperature fuels they are all trying to use to put more stuff in orbit for less money.

USACA: PSI has an ambitious vision for scaling up this work in the next few years.

George Rodgers: We want to supply flying machines. Right now, we are living on contracted research. We’re doing well with contracts. We’re in the game on almost all the major hypersonic programs. We have unique capabilities to help with the affordability and the cycle time.

John Steinbeck: And we think our ultra-high temperature material gives us a leg up for future systems that are well beyond Mach 5.

USACA: What are you aiming for in terms of cycle time?

George Rodgers: Right now, we are not fully vertically integrated. We outsource a couple of key processes. When we’re fully vertically integrated, our cycle time’s going to be about a month.

Reached after the interview, Rodgers continued, “Bringing all of the processes required for CMC production in-house represents a significant capital investment and the equipment has very long lead times. We will make those investments when we have a design win to size the equipment appropriately and provide our customers the best value.”

Press Release

Physical Sciences Inc. and their university partner propose to develop a chemical model that accurately predicts the performance of hydroxyl terminated polybutadiene (HTPB) polymer commonly used as a propellant binder in rocket motors. The model will utilize chemical and physical data from HTPB feedstock to predict propellant cure kinetics, mechanical properties, and aging performance. The model will incorporate an algorithm with the capability to provide formulation recommendations to achieve cured propellants with precise performance specifications. In Phase I, PSI conducted a Design Of Experiments (DOE) by independently modifying the chemical functionalities on HTPB while collecting curing and performance data. This comprehensive data set was used to determine statistically significant associations that correlate HTPB chemical variables with gumstock performance properties. The DOE results gathered in Phase I will be used to build and validate a predictive software model in Phase II. This HTPB predictive algorithm will serve as a tool that will enable formulators to adjust propellant formulation parameters to achieve performance properties without the schedule and cost risks associated with rework. Successful development of the proposed HTPB predictive algorithm will provide the Navy with a critical technology that reduces costs and risks throughout the DoD tactical missile supply chain.

For more information contact:

Dr. Colin Hessel
Group Leader, Advanced Interfacial Materials
chessel@psicorp.com
Physical Sciences Inc.
Office: (978) 689-0003

Acknowledgement of Sponsorship: This work is supported under a contract with the Naval Air Warfare Center (NAVAIR). This support does not constitute an express or implied endorsement on the part of the Government.

Press Release

Physical Sciences Inc. (PSI) has been awarded a contract from the U.S. Army to develop high energy density resin systems that are suitable for additive manufacturing of explosive and propellant formulations.

One approach is to tailor energetic prepolymers and plasticizers to enable rapid curing. This would lower manufacturing costs, increase manufacturing throughput as well as increase the range and lethality of the system. Physical Sciences Inc. (PSI) and their university partner successfully executed a Phase I program that developed scalable technologies to enable additive manufacturing of energetic resin systems. PSI demonstrated energetic resin systems with high energy density components that can be rapidly cured via thermal and/or UV processes. In Phase II, PSI will scale up the energetic resin system components to the pilot production scale and qualify the materials for insertion into explosive and propellant formulations through various thermochemical, sensitivity, and compatibility testing. PSI will perform iterative development in collaboration with the Army technical leads and demonstrate commercial viability of production at scale via techno-economic analysis. PSI will work with DoD primes and private sector companies to advance the TRL and transition the technology into commercial production. The Phase II design and transition plan will guide Phase III efforts, focusing on qualification of the material in explosive/propellant applications selected by the US Army.

For more information contact:

Dr. Dorin Preda
Vice President, Materials Technologies
dpreda@psicorp.com
Physical Sciences Inc.
Office: (978) 689-0003

Acknowledgement of Sponsorship: This work is supported under a contract with the U.S. Army. This support does not constitute an express or implied endorsement on the part of the Government.