In an era defined by technological innovation, geopolitical tensions, and a global shift towards sustainability, the aerospace and defense (A&D) market stands as a pivotal arena driving groundbreaking advancement and strategic investment.
The A&D market witnessed significant growth, expanding by 7.7% from $856.3 billion in 2022 to $922.2 billion in 2023. Additionally, mergers and acquisitions in the North American A&D market surged after the recovery from Covid-related downturns. Heightened geopolitical challenges including Russia’s invasion of Ukraine, the Israel-Hamas conflict, and tensions in Taiwan, are spurring investments in weapons and next-generation defense capabilities.
Furthermore, the global push towards decarbonizing air travel is fueling innovations, such as fully electric vehicles, hybrid systems using hydrogen and batteries, and advancements in traditional combustion designs, all contributing to transformational efficiency improvements (Cascadia Aerospace and Defense Industry Report, 2024).
A few interesting data points to consider: ·
eVTOLs have reached an 18,000-unit backlog, valued at $111 Billion*
Electrifying all flights under two hours could reduce aviation CO2 emissions by 28%* ·
Satellite constellations are up 1,000% in 4 years* ·
VC investments in space startups up nearly 3,500% in the last decade* ·
Defense focused VC is increasing at a rate of 30% / yr. in response to global conflicts*
*(UP Partners, 2024)
These megatrends amplify the needs for transformational advancements in material science, including lighter and more robust thermal protection systems (TPS). Thermal protection became a household topic on January 28th , 1986, at 11:39 am EST when Thiokol’s (now Northrop Grumman) O‑ring seals on the engine boosters proved faulty in cold conditions.
Many American school kids, myself included, watched the events unfold on live TV with classmates and teachers. It was a particularly promoted event at schools because Christa McAuliffe, the first school teacher in Space, was one of the crew members.
Besides highlighting the importance of TPS, the disaster also put a pause on government investing in space exploration. Harvard Business School published an enlightening case study for those that want to learn more: Group Process in the Challenger Launch Decision. More recently, Tom Cruise did his part to highlight the importance of TPS in Top Gun Maverick, as he pushed the Darkstar to Mach 10 to keep his programs funding (spoiler alert… Maverick pulls it off).
This is where Blueshift comes in. Blueshift is a technology leader in thermal and RF materials, as well as the trusted thermal material specialist in our field. Our customers trust us to produce high-performing, easy-to-apply thermal protection systems that are distinct due to our core technology’s 85% air structure.
All our products are produced in scalable roll-to-roll formats that can be easily converted into complex shapes and parts within our campus, an AS9100D certified fabrication facility in Spencer, Massachusetts. Our material expertise expands further through our ability to provide thermal models and simulate design systems, ultimately optimizing solutions for our customers. Blueshift aims to establish lasting partnerships focused on developing new technology and fostering innovative ideas in tandem with our customers.
Identifying a gap in the market
Blueshift began in 2013 when we recognized a significant gap within efforts to lightweight designs in the Aerospace industry. We were driven by a passion for improving the efficiency of air and space travel and aimed to assist product designers in addressing their emerging, complex issues, particularly in thermal management.
During this period, there was considerable excitement surrounding investments in private space companies, such as SpaceX, Blue Origin and Virgin Galactic. At this time, fast-moving innovators without billionaire-backing, such as Rocket Lab, also emerged to challenge the status quo. (For a great read on this era check out “When the Heavens Went on Sale: The Misfits and Geniuses….”). Until then, aerospace companies had relied on legacy solutions like cork and specialty paints, which had seen little innovation for decades. Recognizing this technological stagnation, we saw an opportunity for disruption. Thus, we created our flagship technology, AeroZero®.
Thermal Protection vs Insulation
Thermal Protection differs significantly from insulation, a crucial distinction that took us time to fully grasp. Traditional insulation primarily addresses steady state, continuous temperatures – think of the familiar pink insulation at Home Depot, measured by its R‑value.
However, when designing TPS for our customers, we avoid discussions centered on R‑value. Instead. we focus on managing shorter-duration extreme temperature cycles and spikes. This involves analyzing factors such as the heat source responsible for the thermal event, its duration, temperature distribution, proximity to the protected area, required temperature differential needed, and more. Each thermal event type–whether its aeroheating, direct or indirect flame exposure, radiant heat, direct contact, conduction, or convection–requires nuanced performance attributes. Terms such as emissivity, absorption, cryogenics, diffusivity, and conductivity form part of our lexicon at Blueshift.
What is so special about Air?
Product designers appreciate two wonderful attributes of air: thermal conductivity and RF transparency. Historically, designers engineered air gaps to aid in thermal management.
Blueshift now offers designers an easy-to-use, low-profile, and flexible method to create these air gaps. With an estimated 300 trillion air pockets in a standard 165-micron A4 size sheet, and comprising over 85% air, our AeroZero® technology effectively mimics structured air.
The material inherits most of its properties of air itself—such as low density, low thermal conductivity, and extremely low dielectric properties, while showcasing impressive gram for gram mechanical strength. Most of our products are a sandwich of AeroZero with substrates and superstrates to create multi-layer multi-functional products. For example, graphite, aluminum, and flame barriers serve as functional materials in our Thermal Protection Systems with AeroZero acting as the “Intel on the inside”.
Our proprietary thermal protection systems protect critical lightweight structures and components in air and space vehicles from transient flame and thermal events, with temperatures ranging from minus 200 °C to over 2,000 °C. Our customers are using our product in various applications, including leading edges, battery compartments, hydrogen fuel tanks, aircraft skins, tubes, engine areas, busbars, cables, composite housings, metals, and structural barriers. Our systems also help to mitigate fire propagation from thermal runaway in power-dense batteries.
CFOs love our solutions too
It’s critical that our solutions save our customers money. Having the best solution isn’t sufficient; Blueshift must provide excellent value and scalability. Saving weight and space on an aircraft is a pretty straightforward calculation.
Additionally, we reduce integration time compared to traditional options. Some customers report needing 1,000s of man-hours for gluing and curing with other options, while AeroZero® TPS is as simple as peel and stick. We also enable customers to use lower-temperature base materials, such as a off-the-shelf carbon fiber resin systems, rather than having to invest in higher-temp, and more expensive resin systems.
Reflecting on the Challenger disaster, the financial benefits of advanced material science technology weren’t a major focus when NASA was only building a few vehicles annually. However, the vast scale of diverse planned build schedules creates highly favorable economics. As the number of vehicles being built reaches the thousands, CFOs appreciate the financial advantages.
Looking to the Future
For those of us that watched the Challenge disaster live, it’s hard to believe it was 40 years ago. That milestone also helps us to understand why there was a significant lull in material science advancements in TPS. Aircraft and Spacecraft are closely related, and the revolution happening in aircraft in the 2020s mirrors the advancements in spacecraft during the 2010s.
Boeing first pitched the concept of the 737 in 1964, which is still a flagship aircraft model in 2024, highlighting their pivotal role alongside Airbus in aircraft design, similar to NASA’s role in spacecraft design.
Now it’s time to hold onto our hats and enjoy the ride. Billions are being invested to fundamentally change air mobility. The vision of an integrated terrestrial and non-terrestrial ecosystem is taking shape, necessitating new forms of mobility linking Low Earth Orbit and the ground. Looking ahead, the industry’s landscape promises groundbreaking advancements in advanced air mobility, sustainable air travel, satellite constellations, and defense capabilities.
The Vertical Flight Society counts over 900 entrants in the AAM industry, with new ones added on a weekly basis (Index, Advanced Air Mobility Reality). Collaborative initiatives among industry leaders, startups, and investors are fueling innovation and reshaping the aerospace frontier. For an illuminating podcast on this subject check out Motley Fools’ featuring Sierra Space’s CEO, Tom Vice: (“To LEO and Beyond — Motley Fool Money.”).
The aerospace and defense sector is undergoing a profound transformation fueled by technological advancements and global shifts, particularly the resurgence of global interest in space exploration and geopolitical conflict. This renewed focus has spurred the development of innovative solutions across the industry.
Our AeroZero® technology stands as a testament to this evolution, redefining thermal protection systems critical for modern aviation and space missions. Our commitment extends beyond providing cutting-edge solutions; we strive to inspire confidence in our customers regarding their thermal needs, enabling them to create aircraft that are not only efficient but also safe.
Our dedication aligns with the mission to decarbonize air travel and enhance overall structural efficiency and safety. Reach out to Blueshift with any questions and join us in developing the next era of thermal technologies!
References:
Group Process in the Challenger Launch Decision (A) — Case — Faculty & Research — Harvard Business School. https://www.hbs.edu/faculty/Pages/item.aspx?num=29356. Accessed 16 Apr. 2024.
Index, Advanced Air Mobility Reality. “Advanced Air Mobility Reality Index.” Advanced Air Mobility Reality Index, https://aamrealityindex.com/aam-reality-index. Accessed 16 Apr. 2024.
Cascadia Aerospace and Defense Industry Report. Cascadia Capital, 2024, p. 66. “To LEO and Beyond — Motley Fool Money.” The Motley Fool, https://www.fool.com/podcasts/motley-fool-money/2024–03-30-to-leo-and-beyond/. Accessed 16 Apr. 2024.
UP Partners. The Moving World Report 2024. 2024, p. 147. “When the Heavens Went on Sale: The Misfits and Geniuses….” Goodreads, https://www.goodreads.com/book/show/62050244-when-the-heavens-went-on-sale. Accessed 16 Apr. 2024
