Kansas City, Kansas Patent of the Year – 2024/2025

Raven Space Systems Inc. has been awarded the 2024/2025 Patent of the Year for its breakthrough in aerospace manufacturing. Their invention, detailed in U.S. Patent No. 12076926, titled ‘Systems and methods for three dimensional printing using microwave assisted deposition’, utilizes microwave-assisted deposition (MAD) to revolutionize 3D printing of high-performance composite materials.

Traditional methods for curing aerospace-grade composites can take days and require extensive tooling. Raven’s MAD technology cures thermoset and preceramic composites instantly during the 3D printing process, significantly reducing production time and waste. This advancement enables rapid manufacturing of components for hypersonic vehicles, satellites, and space capsules.

The MAD system employs a microwave resonance cavity to cure carbonaceous nanocomposite thermosets as they are extruded, ensuring precise control over the material properties. Sensors monitor the extrusion temperature, allowing real-time adjustments for optimal curing. This process supports materials like epoxy, phenolic, silicone, silicon carbide, and carbon-carbon composites.

Founded in 2020 by Blake Herren and Ryan Cowdrey, Raven has secured over $5 million in funding from NASA, the U.S. Air Force, and the National Science Foundation. The company is developing 3D-printed aeroshells for hypersonic flight testing under a $1.8 million AFRL contract. A demonstration mission planned for 2025 aims to test a 3D-printed space capsule’s reentry capabilities.

Raven’s innovation addresses critical supply chain challenges in the aerospace and defense sectors, offering a scalable solution for producing complex, high-temperature components. By integrating MAD technology into manufacturing processes, the company is poised to transform the production of advanced composite structures.