M.E.R.I.N.O.
Materials Engineered for Re-Entry using Innovative Needling Operations
Advancing American heat shield manufacturing
American Felt & Filter Company (AFFCO) has received a NASA Small Business Innovation Research (SBIR) Phase I award. Under it, we are developing domestic manufacturing for needle-punched carbon and phenolic fiber felts used in next-generation spacecraft heat shields.
The work builds on MERINO (Materials Engineered for Re-entry using Innovative Needling Operations), a flexible thermal protection material developed at NASA Ames Research Center and also known as PICA-Flex, as described on NASA's Technology Transfer site.
The challenge
According to NASA, for about three decades phenolic impregnated carbon ablator (PICA) has been the state of the art for protecting spacecraft during atmospheric entry. Rigid PICA works, but making it is slow and costly.
Each part needs a lengthy phenolic resin infusion and complex equipment.
Rigid tiles must be machined and fitted, which adds integration time and seams.
Production can take six months or more.
A flexible alternative built on felting
NASA's MERINO approach uses needle-punch felting in place of resin infusion, producing a thermal protection material that can be installed as a flexible blanket. NASA cites these benefits:
Production in weeks rather than months
Lower cost for low-to-moderate heat flux missions, including commercial space
Faster installation over large areas
Fewer gaps and seams
Source: NASA Technology Transfer Program, TOP2-331
Our Phase I work
Needle punching is what we do every day. Under our Phase I award, we are applying that expertise to manufacturing materials for this new class of heat shield.
Why AFFCO
Needle-punch experts since 1890. We have produced needled and pressed felts in the USA for more than 135 years.
Aerospace quality systems. We operate under AS9100 and are ISO 9001 certified.
In-house R&D and lab. Our engineers and laboratory take materials from concept to production.
Made in America. Every felt product we make is manufactured at our New Windsor, New York facility, supporting a domestic supply chain for critical space materials.
Where this technology applies
Forebody and aftbody thermal protection for atmospheric-entry spacecraft
Commercial crew and cargo capsules
Planetary probes and space exploration missions
Other high-heat environments that need lightweight, conformable thermal protection
Project at a glance
Program: NASA SBIR Phase I
Topic: FY26-26 BAA Appendix 26B-1 Subtopic LAND.3.S26B
Period of performance: Sept 2026 - March 2027
Technology origin: MERINO / PICA-Flex, NASA Ames Research Center
Work with us
We are looking for aerospace primes, commercial space companies and research partners interested in flexible thermal protection materials. Contact us to discuss samples, collaboration or Phase II opportunities.
American Felt & Filter Company · 361 Walsh Avenue, New Windsor, NY 12553 · (845) 561-3560 · EMAIL: questions@affco.com
This material is based upon work supported by the National Aeronautics and Space Administration under a NASA SBIR Phase I award. Any opinions, findings and conclusions or recommendations expressed on this page are those of American Felt & Filter Company and do not necessarily reflect the views of NASA. Reference to NASA technology does not imply NASA endorsement of AFFCO or its products.
Technology information on this page is drawn from NASA's publicly available listing: NASA Technology Transfer Program, TOP2-331, Flexible Phenolic Intermingled Carbon Ablators (PICA-Flex).