That Aerodynamic Spacecraft – Thank Composites for That

Spacecraft are aerodynamic by design. To get a spacecraft out of the atmosphere and into space, engineers need to overcome both gravity and drag. Vehicles need to be as aerodynamic as possible to overcome the forces of nature. Thanks to aerospace composites, it is possible.

Composite materials, in general, lend themselves very well to intricate designs that aren’t possible with metals. Aerospace composites go one step further to make designs stronger, more temperature resistant, and able to withstand the stresses of space flight.

Key Considerations in Aerodynamics

Making a spacecraft aerodynamic is all about reducing friction. The less friction between air and external surface, the more efficiently a spacecraft flies. Efficient flight reduces fuel, spacecraft stress, and the time it takes to get a vehicle to its destination.

As you might expect, there are some key considerations engineers need to account for. Here are the two most important:

1. Exterior Surfaces

The enemy of efficient flight is friction. Friction occurs as air moves across a vehicle’s surface. The smoother that surface, the less friction there tends to be. Aerospace composite materials are ideal for friction-reducing designs because:

• They reduce the need for friction-causing components like rivets and surface joints. Such components are common when manufacturing with steel and aluminum.
• They reduce drag through smoother surfaces that improve overall aerodynamic efficiency. Composite materials can be smoothed and polished quite finely.
• They increase fuel efficiency and range by reducing drag. Vehicles can get into orbit more quickly and easily without burning as much fuel.

Many of the same principles designers rely on to increase spacecraft aerodynamics are applied in the automotive industry as well. Aerodynamic designs lead to cars that are more fuel efficient and more responsive.

2. Design Complexity

Aerodynamic design can be quite flexible. For example, the aerodynamics of a rocket are pretty straightforward. But the aerodynamics of a stealth fighter are considerably more complicated. Aerospace composites facilitate both through their ability to accommodate complex designs. Consider the following:

• Composites can be molded into exceptionally complex shapes and forms.
• Design flexibility allows engineers to optimize lines and contours.
• Composites work very well for producing smooth aerodynamic profiles.

Although the space shuttle program has long been shuttered, its vehicles represent some of the most revolutionary aerodynamic designs in spaceflight. Without composites, none of the shuttle vehicles that made the trip to space would have ever gotten there.

Composite Fringe Benefits

Although the point of this post is to discuss the role aerospace composites play in designing aerodynamic spacecraft, there are some additional ‘fringe benefits’ worth mentioning. Aerospace composites allow for aerodynamic vehicles without compromising strength, durability, and efficiency. Composites offer:

• Weight Reductions – Lightweight composites are still stronger and more rigid than metals. They offer the higher strength-to-weight ratio that makes it possible to travel into space. Spacecraft are also more maneuverable thanks to their lower weight.
• Structural Integrity – Even when aerodynamics need to be considered, composite materials maintain structural integrity and shape even under the harshest conditions. They resist fatigue and corrosion better than metals, guaranteeing more consistent performance.
• Property Customization – Composite materials can be customized to stress specific properties. For example, just by modifying layup orientation, engineers can maximize stiffness and strength while still maintaining aerodynamics.

Spacecraft need to be aerodynamic to do what they do. As such, engineers need to design vehicles with minimal drag, reduced weight, and the structural integrity to withstand considerable punishment. It is all made possible through aerospace composites made by companies like ours. Next time you see a video of a rocket being launched into space, remember that composites are largely responsible.