Plasma Processes and the Johns Hopkins Applied Physics Lab (JHAPL) began a collaboration in 2006 to develop and apply an optical coating to the carbon-carbon composite heat shield of NASA’s Parker Solar Probe.  The probes’ mission is to fly seven times closer to the sun than any other spacecraft, while surviving temperatures > 2,500 degrees Fahrenheit at its closest pass.

To survive the extreme environment of the sun’s corona, the team was tasked with finding a high-temperature coating providing specific optical properties. After perfecting the chemical composition, Plasma Processes was tasked with synthesizing the custom powder. The next step was scaling the coating process from a 1-inch x 1-inch square to a 9-foot x 9-foot full scale heat shield. Plasma Processes coated the first full-scale prototype in 2013; followed by rigorous testing  by JHAPL to verify the structure and coating could handle extreme launch vibrations and cryogenic temperatures.  The team validated the coating and process for space flight hardware on the Flight Qualification Unit in 2015. The Flight Unit was coated and delivered for integration in the summer of 2017.

https://www.msn.com/en-us/news/technology/nasa-s-parker-solar-probe-becomes-first-spacecraft-to-touch-the-sun/ar-AAROvS0?ocid=ientp

Plasma Processes’ green propellant technology was showcased in the Missile Defense Agency’s Tech Update, a quarterly newsletter for MDA technology transfer. The technology, funded by MDA in 2008, features combustion subcomponents compatible with non-toxic, “green” propellants with a goal of replacing hydrazine. Plasma anticipates the “green” propellant systems will be used for satellite insertion and station-keeping, reaction control, auxiliary power, and divert and attitude control.

As part of Plasma Processes’ continuous improvement initiative, key managers visited the Sur-Seal manufacturing plant in Cincinnati, Ohio to learn more about lean manufacturing implementation and best practices. The one-day immersion event comprised an in-depth plant tour, team-building exercises, and the opportunity to engage Sur-Seal’s employees on its thinking behind lean and various applications.

An industry leader in the application of lean principles, Sur-Seal was awarded the Association for Manufacturing Excellence Award in 2012. The AME Manufacturing Excellence Award recognizes North American manufacturing plants that have demonstrated excellence in manufacturing and business. The primary focus of the award is to acknowledge continuous improvement, best practices, creativity and innovation.

Plasma Processes’ own lean journey is being led by Mark Preston of Riverwood Associates Consulting based in Atlanta, Georgia. During the event, Adam Reed, Production Manager, received recognition for his yellow belt achievement.

Tim McKechnie, president of Plasma Processes, was honored as a fellow of ASM International (formerly the American Society of Metals) during its Tuesday, Oct. 29 awards dinner in Montreal, Canada. The distinction of fellow is conferred upon members who have made distinguished contributions to materials science and engineering.  McKechnie, a Vanderbilt University alum, was selected for “pioneering development of thermal spray coatings and establishing a successful materials engineering company”.  Mr. McKechnie founded Plasma Processes in 1993 to develop engineered materials solutions for the aerospace, defense, energy, medical and commercial industries.