Optimization of bistable clamp for aerospace thermal systems

Spacecraft, launch vehicles, and hypersonic craft utilize thermal protection systems (TPS) with tiles to prevent thermal hazards at high speeds. Traditionally, manufacturers attach tiles using silicone adhesives. This paper proposes a bistable compliant clamp for secure, rapid tile exchange on engineered surfaces without chemical adhesives. Computational design optimization implemented a hyperelastic solid model with yield constraint, and applied sequential sweeps of geometric parameters. The optimized clamp was prototyped in polylactic acid (PLA, \({\sigma }_{Y}=43.5\) ${\sigma }_Y=43.5$ MPa, \(E=1.014\) $E=1.014$ GPa), with retention force measured at 53.41 N for a device with a mass of 47.3 g and footprint of 789 mm².