{"id":64938,"date":"2024-12-02T11:17:00","date_gmt":"2024-12-02T10:17:00","guid":{"rendered":"https:\/\/xometry.pro\/stories\/trace-transpiration-cooling-technology\/"},"modified":"2024-12-02T12:06:42","modified_gmt":"2024-12-02T11:06:42","slug":"trace-transpiration-cooling-technology","status":"publish","type":"stories","link":"https:\/\/xometry.pro\/en-tr\/stories\/trace-transpiration-cooling-technology\/","title":{"rendered":"Pioneering Transpiration Cooling Technology for Space Flight with The TRACE Project"},"content":{"rendered":"<div role=\"navigation\" aria-label=\"Table of Contents\" class=\"simpletoc wp-block-simpletoc-toc\"><h2 class=\"simpletoc-title\">Table of Contents<\/h2>\n<ul class=\"simpletoc-list\">\n<li><a href=\"#h-the-promise-of-transpiration-cooling\">The Promise of Transpiration Cooling<\/a>\n\n<\/li>\n<li><a href=\"#from-concept-to-reality-traces-journey\">From Concept to Reality: TRACE\u2019s Journey<\/a>\n\n<\/li>\n<li><a href=\"#what-makes-trace-groundbreaking\">What Makes TRACE Groundbreaking<\/a>\n\n<\/li>\n<li><a href=\"#lessons-and-advice-for-future-space-innovators\">Lessons and Advice for Future Space Innovators<\/a>\n<\/li><\/ul><\/div>\n\n\n<p>TRACE, or the TRAnspiration Cooling Experiment, is designed to test transpiration cooling technology for heat shields. The experiment involves a free-flying unit (FFU) deployed from a rocket to measure heat dissipation during atmospheric re-entry at speeds up to <a href=\"#Mach3.2\">Mach 3.2<\/a>. The team aims to enhance heat management for spacecraft re-entry, recognizing the potential of transpiration cooling as a reusable and efficient alternative to traditional heat shields. This breakthrough could reduce costs and material requirements for future space missions.<\/p>\n\n\n    <aside data-id=\"Mach3.2\" class=\"aside-popup\">\r\n        <div class=\"popup-content\">\r\n            <div class=\"popup-close-btn\">\r\n                <img decoding=\"async\" src=\"https:\/\/xometry.pro\/wp-content\/themes\/xometry\/assets\/images\/cross.svg\" alt=\"close-popup\">\r\n            <\/div>\r\n            <div>\r\n                <div class=\"popup-text\">Mach 3.2 refers to a speed 3.2 times the speed of sound, roughly 3,920 km\/h (2,435 mph) at sea level, commonly experienced during high-speed atmospheric re-entry.<\/div>            <\/div>\r\n                    <\/div>\r\n    <\/aside>\r\n\n\n<h2 class=\"wp-block-heading\" id=\"h-the-promise-of-transpiration-cooling\"><strong>The Promise of Transpiration Cooling<\/strong><\/h2>\n\n\n<p>Heat shields are essential for spacecraft designed to land on other planets or return safely to Earth. They protect against the intense aerothermal loads caused by the high kinetic energy of orbital re-entry, ensuring this energy is safely dissipated before the spacecraft reaches the surface. Current heat protection systems often require complex maintenance or are single-use, which limits their reusability in an era focused on sustainable space exploration.<\/p>\n\n\n\n<p>Transpiration cooling offers a revolutionary alternative to ablative systems, which rely on destructive pyrolysis to manage heat. Instead, it expels gas through the spacecraft\u2019s surface, creating a cooling layer that protects against intense thermal loads during re-entry.<\/p>\n\n\n\n<figure class=\"wp-block-image size-large\"><div class=\"wp-block-image__wrap\"><img decoding=\"async\" width=\"1024\" height=\"685\" src=\"https:\/\/xometry.pro\/wp-content\/uploads\/2024\/11\/trace-team-1024x685.png\" alt=\"Part of the TRACE team at the roll-out of the REXUS 31 rocket during the launch campaign\" class=\"wp-image-64678\" srcset=\"https:\/\/xometry.pro\/wp-content\/uploads\/2024\/11\/trace-team-1024x685.png 1024w, https:\/\/xometry.pro\/wp-content\/uploads\/2024\/11\/trace-team-300x201.png 300w, https:\/\/xometry.pro\/wp-content\/uploads\/2024\/11\/trace-team-768x514.png 768w, https:\/\/xometry.pro\/wp-content\/uploads\/2024\/11\/trace-team-1536x1027.png 1536w, https:\/\/xometry.pro\/wp-content\/uploads\/2024\/11\/trace-team.png 1865w\" sizes=\"(max-width: 1024px) 100vw, 1024px\" \/><a class=\"wp-block-image__fancy-box-button\" href=\"https:\/\/xometry.pro\/wp-content\/uploads\/2024\/11\/trace-team.png\" data-fancybox=\"gallery-64938\" data-caption=\"Part of the TRACE team at the roll-out of the REXUS 31 rocket during the launch campaign\" aria-label=\"Open full image\"><img src=\"https:\/\/xometry.pro\/wp-content\/uploads\/2024\/11\/trace-team.png\" class=\"wp-block-image__fancy-box-button-thumbnail wp-post-image\" alt=\"\" loading=\"lazy\" decoding=\"async\"><svg class=\"wp-block-image__fancy-box-button-icon\" xmlns=\"http:\/\/www.w3.org\/2000\/svg\" width=\"18\" height=\"18\" viewBox=\"0 0 18 18\" fill=\"none\" aria-hidden=\"true\">\r\n               <path d=\"M0 2V6H2V2H6V0H2C0.895 0 0 0.895 0 2ZM2 12H0V16C0 17.105 0.895 18 2 18H6V16H2V12ZM16 16H12V18H16C17.105 18 18 17.105 18 16V12H16V16ZM16 0H12V2H16V6H18V2C18 0.895 17.105 0 16 0Z\" fill=\"#092C47\"\/>\r\n             <\/svg><\/a><\/div><figcaption class=\"wp-element-caption\">Part of the TRACE team at the roll-out of the REXUS 31 rocket during the launch campaign<\/figcaption><\/figure>\n\n\n<h2 class=\"wp-block-heading\" id=\"from-concept-to-reality-traces-journey\"><strong>From Concept to Reality: TRACE\u2019s Journey<\/strong><\/h2>\n\n\n<p>The TRACE concept originated from a bachelor thesis developed in collaboration with the <a href=\"https:\/\/www.dlr.de\/en\" target=\"_blank\" rel=\"noreferrer noopener\">German Aerospace Center (DLR)<\/a>. This initial work explored the feasibility of a transpiration cooling system for re-entry applications on a REXUS rocket. We refined these early ideas, setting specific experimental goals and transforming theoretical designs into practical, testable components.<\/p>\n\n\n\n<p>Developing TRACE involved overcoming several technical challenges:<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li><strong>Miniaturization<\/strong>: Ensuring all systems fit within a compact capsule without compromising functionality.<\/li>\n\n\n\n<li><strong>Parachute deployment<\/strong>: Testing and ensuring stable deployment of the high-speed parachute at supersonic speeds.<\/li>\n\n\n\n<li><strong>Aerodynamics<\/strong>: Optimizing the capsule\u2019s shape to minimize drag and maintain a stable trajectory.<\/li>\n\n\n\n<li><strong>Production delays<\/strong>: Navigating unavoidable delays by adjusting timelines and focusing on other project areas.<\/li>\n<\/ul>\n\n\n\n<figure class=\"wp-block-image size-large\"><div class=\"wp-block-image__wrap\"><img decoding=\"async\" width=\"1024\" height=\"776\" src=\"https:\/\/xometry.pro\/wp-content\/uploads\/2024\/11\/cad-model-trace-1024x776.png\" alt=\"CAD model of TRACE\" class=\"wp-image-64666\" srcset=\"https:\/\/xometry.pro\/wp-content\/uploads\/2024\/11\/cad-model-trace-1024x776.png 1024w, https:\/\/xometry.pro\/wp-content\/uploads\/2024\/11\/cad-model-trace-300x227.png 300w, https:\/\/xometry.pro\/wp-content\/uploads\/2024\/11\/cad-model-trace-768x582.png 768w, https:\/\/xometry.pro\/wp-content\/uploads\/2024\/11\/cad-model-trace.png 1262w\" sizes=\"(max-width: 1024px) 100vw, 1024px\" \/><a class=\"wp-block-image__fancy-box-button\" href=\"https:\/\/xometry.pro\/wp-content\/uploads\/2024\/11\/cad-model-trace.png\" data-fancybox=\"gallery-64938\" data-caption=\"CAD model of TRACE\" aria-label=\"Open full image\"><img src=\"https:\/\/xometry.pro\/wp-content\/uploads\/2024\/11\/cad-model-trace.png\" class=\"wp-block-image__fancy-box-button-thumbnail wp-post-image\" alt=\"\" loading=\"lazy\" decoding=\"async\"><svg class=\"wp-block-image__fancy-box-button-icon\" xmlns=\"http:\/\/www.w3.org\/2000\/svg\" width=\"18\" height=\"18\" viewBox=\"0 0 18 18\" fill=\"none\" aria-hidden=\"true\">\r\n               <path d=\"M0 2V6H2V2H6V0H2C0.895 0 0 0.895 0 2ZM2 12H0V16C0 17.105 0.895 18 2 18H6V16H2V12ZM16 16H12V18H16C17.105 18 18 17.105 18 16V12H16V16ZM16 0H12V2H16V6H18V2C18 0.895 17.105 0 16 0Z\" fill=\"#092C47\"\/>\r\n             <\/svg><\/a><\/div><figcaption class=\"wp-element-caption\">CAD model of TRACE<\/figcaption><\/figure>\n\n\n<h2 class=\"wp-block-heading\" id=\"what-makes-trace-groundbreaking\"><strong>What Makes TRACE Groundbreaking<\/strong><\/h2>\n\n\n<p>TRACE incorporates several advanced technical features to meet the extreme demands of re-entry testing. The capsule is engineered to reach speeds of up to <a href=\"#Mach3\">Mach 3<\/a>, generating intense heating conditions in the dense atmosphere to rigorously evaluate the cooling system. Its high ballistic coefficient ensures stability and sustained velocity throughout descent. <\/p>\n\n\n\n<p>At the core of its innovation is a transpiration cooling system that uses Argon gas to shield heat-exposed surfaces, safeguarding the structure from severe thermal loads. Complementing this is a supersonic parachute, capable of deploying at <a href=\"#Mach2\">Mach 2<\/a> around 10 km altitude, which ensures a controlled descent and enables reliable data collection during re-entry.<\/p>\n\n\n    <aside data-id=\"Mach3\" class=\"aside-popup\">\r\n        <div class=\"popup-content\">\r\n            <div class=\"popup-close-btn\">\r\n                <img decoding=\"async\" src=\"https:\/\/xometry.pro\/wp-content\/themes\/xometry\/assets\/images\/cross.svg\" alt=\"close-popup\">\r\n            <\/div>\r\n            <div>\r\n                <div class=\"popup-text\">Approximately 3,675 km\/h (2,284 mph) at sea level<\/div>            <\/div>\r\n                    <\/div>\r\n    <\/aside>\r\n\n\n    <aside data-id=\"Mach2\" class=\"aside-popup\">\r\n        <div class=\"popup-content\">\r\n            <div class=\"popup-close-btn\">\r\n                <img decoding=\"async\" src=\"https:\/\/xometry.pro\/wp-content\/themes\/xometry\/assets\/images\/cross.svg\" alt=\"close-popup\">\r\n            <\/div>\r\n            <div>\r\n                <div class=\"popup-text\">Approximately 2,450 km\/h (1,522 mph) at sea level<\/div>            <\/div>\r\n                    <\/div>\r\n    <\/aside>\r\n\n\n<div id=\"yW5oGMSsS_s-69ddfa940abd8\" data-video-id=\"yW5oGMSsS_s\" class=\"ma-gdpr-youtube-wrapper\" style=\"width:100%;height:56.25%;padding-top:56.25%;\" data-new-window=\"\" data-yt-parameters=\"WyJtYXgtd2lkdGg9XHUyMDFjNzAwcHhcIiJd\"><picture class=\"ma-gdpr-youtube-thumbnail\"><source media=\"(min-width:320px)\" type=\"image\/webp\" srcset=\"\/\/xometry.pro\/wp-content\/uploads\/ma-gdpr-youtube-thumbnails\/yW5oGMSsS_s\/yW5oGMSsS_s_sddefault.webp\"><source media=\"(min-width:320px)\" type=\"image\/jpeg\" srcset=\"\/\/xometry.pro\/wp-content\/uploads\/ma-gdpr-youtube-thumbnails\/yW5oGMSsS_s\/yW5oGMSsS_s_sddefault.jpg\"><source media=\"(min-width:240px)\" type=\"image\/webp\" srcset=\"\/\/xometry.pro\/wp-content\/uploads\/ma-gdpr-youtube-thumbnails\/yW5oGMSsS_s\/yW5oGMSsS_s_hqdefault.webp\"><source media=\"(min-width:240px)\" type=\"image\/jpeg\" srcset=\"\/\/xometry.pro\/wp-content\/uploads\/ma-gdpr-youtube-thumbnails\/yW5oGMSsS_s\/yW5oGMSsS_s_hqdefault.jpg\"><img decoding=\"async\" src=\"\/\/xometry.pro\/wp-content\/uploads\/ma-gdpr-youtube-thumbnails\/yW5oGMSsS_s\/yW5oGMSsS_s_mqdefault.jpg\" alt=\"\" title=\"\"><\/picture><svg class=\"ma-gdpr-youtube-button\"><use xlink:href=\"#ma-gdpr-youtube-play-button\"><\/use><\/svg><div class=\"ma-gdpr-youtube-notice\" style=\"font-size:.7em;\"><\/div><\/div>\n\n\n\n<p>TRACE stands out with pioneering features that set it apart from other experiments. It is among the first in-flight tests of transpiration cooling as a heat shield, representing a significant step toward reusable thermal protection systems for high-speed re-entry. Its compact, bean-shaped pressure vessel, manufactured using metal 3D printing (similar to SLM but with a continuous laser) and Titan Grade 5 (Ti6Al4V), demonstrates the precision and versatility of advanced 3D printing in creating complex structural configurations.&nbsp;<\/p>\n\n\n\n<p>Additionally, the supersonic parachute, designed for deployment at Mach 2, ensures a safe descent and enables consistent data transmission even under extreme high-speed conditions.<\/p>\n\n\n<h2 class=\"wp-block-heading\" id=\"lessons-and-advice-for-future-space-innovators\"><strong>Lessons and Advice for Future Space Innovators<\/strong><\/h2>\n\n\n<p>As a team, we take immense pride in the engineering and dedication that culminated in TRACE&#8217;s successful launch from <a href=\"https:\/\/www.esa.int\/Education\/Rexus_Bexus\/Eight_student_experiments_launched_on_sounding_rockets\" target=\"_blank\" rel=\"noreferrer noopener\">Esrange (Sweden) in March 2024<\/a>. Achieving this milestone demanded exceptional technical precision and unwavering commitment, making the project&#8217;s completion an incredibly rewarding experience. Equally important was the mutual support we provided each other during setbacks and challenges, which strengthened our resilience and unity. These obstacles pushed us to adapt and grow, and this shared perseverance stands as one of our most significant achievements.<\/p>\n\n\n\n<p>Looking to the future, we are excited to embark on TRACER, an evolution of the TRACE project. TRACER will be integrated directly into the rocket, allowing us to investigate and compare multiple cooling media while improving system simplicity and component accessibility. By avoiding overly complex designs, TRACER aims to streamline construction, simplify updates, and foster further innovation in thermal protection systems.<\/p>\n\n\n\n<p>For anyone embarking on a similar project, our key advice is to iterate and test as early as possible. Rapid prototyping provides invaluable feedback, enabling you to identify potential issues and refine your design efficiently. Adopt an agile mindset, remain flexible, and be prepared to adapt based on test results. This iterative approach is essential for achieving a successful outcome in any ambitious project.<\/p>\n\n\n\n<p>Learn more about the <a href=\"https:\/\/www.spaceteamaachen.de\/projects\/trace\" target=\"_blank\" rel=\"noreferrer noopener\">TRACE project<\/a> and <a href=\"https:\/\/www.spaceteamaachen.de\/\" target=\"_blank\" rel=\"noreferrer noopener\">Space Team Aachen<\/a>.<\/p>\n\n\n\n<hr class=\"wp-block-separator has-text-color has-alpha-channel-opacity has-background\" style=\"background-color:#f5f7f8;color:#f5f7f8\"\/>\n\n\n\n<p><strong>Have you worked on or explored solutions for spacecraft systems, from heat management to propulsion or materials engineering? <\/strong>Share your insights about creating the next generation of reusable and efficient spacecraft systems!<\/p>\n\n\n\n<p><\/p>\n","protected":false},"author":50,"featured_media":64693,"comment_status":"open","ping_status":"closed","template":"","c-tag-stories":[2097],"global-tag":[495],"class_list":["post-64938","stories","type-stories","status-publish","has-post-thumbnail","hentry","c-tag-stories-aerospace-en-tr","global-tag-3d-printing-tr"],"acf":[],"yoast_head":"<!-- This site is optimized with the Yoast SEO Premium plugin v26.7 (Yoast SEO v27.3) - https:\/\/yoast.com\/product\/yoast-seo-premium-wordpress\/ -->\n<title>Pioneering Transpiration Cooling Technology for Space Flight | Xometry Pro<\/title>\n<meta name=\"description\" content=\"Hi, my name is Till and I\u2019m a Mechanical Engineer of the TRACE project which tackles cutting-edge challenges in aerospace technology.\" \/>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<link rel=\"canonical\" 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