Embodiments include active protection systems and methods for an aerial platform. An onboard system includes radar modules, detects aerial vehicles within a threat range of the aerial platform, and determines if any of the aerial vehicles are an aerial threat. The onboard system also determines an intercept vector to the aerial threat, communicates the intercept vector to an eject vehicle, and causes the eject vehicle to be ejected from the aerial platform to intercept the aerial threat. The eject vehicle includes alignment thrusters to rotate a longitudinal axis of the eject vehicle to substantially align with the intercept vector, a rocket motor to accelerate the eject vehicle along an intercept vector, divert thrusters to divert the eject vehicle in a direction substantially perpendicular to the intercept vector, and attitude control thrusters to make adjustments to the attitude of the eject vehicle.

A reaction control system (RCS) is provided for use with an air vehicle having a nose portion and a center of gravity aft of the nose portion. The RCS includes a belt element configured for selectively securing the RCS to the nose portion, and also includes a plurality of micro-rocket modules affixed to the belt element, each micro-rocket module being configured for being selectively activated to provide corresponding control moments to the air vehicle when secured to the nose portion thereof. A corresponding air vehicle, and a method for modifying an air vehicle, are also provided.

Embodiments include active protection systems and methods for an aerial platform. An onboard system includes one or more radar modules, detects aerial vehicles within a threat range of the aerial platform, and determines if any of the plurality of aerial vehicles are an aerial threat. The onboard system also determines an intercept vector to the aerial threat, communicates the intercept vector to an eject vehicle, and causes the eject vehicle to be ejected from the aerial platform to intercept the aerial threat. The eject vehicle includes a rocket motor to accelerate the eject vehicle along an intercept vector, alignment thrusters to rotate a longitudinal axis of the eject vehicle to substantially align with the intercept vector, and divert thrusters to divert the eject vehicle in a direction substantially perpendicular to the intercept vector. The eject vehicle activates at least one of the alignment thrusters responsive to the intercept vector.

Embodiments include active protection systems and methods for an aerial platform. An onboard system includes one or more radar modules, detects aerial vehicles within a threat range of the aerial platform, and determines if any of the plurality of aerial vehicles are an aerial threat. The onboard system also determines an intercept vector to the aerial threat, communicates the intercept vector to an eject vehicle, and causes the eject vehicle to be ejected from the aerial platform to intercept the aerial threat. The eject vehicle includes a rocket motor to accelerate the eject vehicle along an intercept vector, alignment thrusters to rotate a longitudinal axis of the eject vehicle to substantially align with the intercept vector, and divert thrusters to divert the eject vehicle in a direction substantially perpendicular to the intercept vector. The eject vehicle activates at least one of the alignment thrusters responsive to the intercept vector.

A projectile, such as a railgun-launched projectile, includes a single-piece body that is additively manufactured. The single piece body includes fuel within it, and one or more cavities for receiving an oxidizer. The body also defines one or more combustion chambers therein for combustion of the fuel and oxidizer as part of a divert thruster system. Thus the projectile is able to fully contain the divert thruster system within the single-piece body without using any hot gas seals as part of the system. The body may also define a cavity for receiving a pressurized fluid, used as part of a cold-gas attitude control system of the projectile. The body may also define passages between the pressurized fluid cavity and other parts of the attitude control system, such as valves and/or nozzles that are outside of the body, for example being aft of the one-piece body.

A method of making an electrical connection includes soldering using channels in a receptacle to direct hot air (or another hot gas) to effect soldering where the electrical connection is to be made. The connection may be made between device electrical contacts of an electrical device, and other contacts, such as receptacle contacts of the receptacle. The connection may be a blind connection, one in which the connected ends of the contacts are hidden or unable to be directly physically accessed, when the connection is made. The electrical connection may be made between device contacts of an electrical device that is inserted into the receptacle, and receptacle electrical contacts that are part of the receptacle. The channels for directing the hot gas to where the soldering occurs may be parts of the receptacle, for example being produced during additive manufacture of the receptacle.

A monolithic attitude control motor frame includes a monolithic structure including an outer surface of revolution and a plurality of side walls defining a plurality of cavities extending radially from the outer surface of revolution. Adjacent cavities of the plurality of cavities share a side wall or side wall portion therebetween. Each of the cavities is configured to receive an attitude control motor. A monolithic attitude control motor system includes a monolithic frame including an outer surface of revolution and a plurality of side walls defining a plurality of cavities extending radially from the outer surface of revolution. The system further includes a plurality of attitude control motors corresponding to the plurality of cavities, such that an attitude control motor of the plurality of attitude control motors is disposed in each cavity of the plurality of cavities.

A thruster has an additively-manufactured housing that includes an integrally-formed nozzle with a burst disk in it. The housing is part of a casing that surrounds and encloses a propellant that is burned to produce pressurized gases that burst the burst disk and produce thrust. The thruster may be placed in a receptacle that defines a recess for receiving the thruster. The receptacle also may be additively manufactured. The thruster and the recess both may be cylindrical, with the housing being closely fit with the cylindrical walls of the receptacle. This may allow some of the structural loads on the housing, such as loads produced by the combustion of the propellant, to be transferred to the adjoining walls of the receptacle. This enables the housing to have less structural strength than if it were to have to contain the pressure from the propellant all on its own.

A projectile, such as a railgun-launched projectile, includes a single-piece body that is additively manufactured. The single piece body includes fuel within it, and one or more cavities for receiving an oxidizer. The body also defines one or more combustion chambers therein for combustion of the fuel and oxidizer as part of a divert thruster system. Thus the projectile is able to fully contain the divert thruster system within the single-piece body without using any hot gas seals as part of the system. The body may also define a cavity for receiving a pressurized fluid, used as part of a cold-gas attitude control system of the projectile. The body may also define passages between the pressurized fluid cavity and other parts of the attitude control system, such as valves and/or nozzles that are outside of the body, for example being aft of the one-piece body.

A method of making an electrical connection includes soldering using channels in a receptacle to direct hot air (or another hot gas) to effect soldering where the electrical connection is to be made. The connection may be made between device electrical contacts of an electrical device, and other contacts, such as receptacle contacts of the receptacle. The connection may be a blind connection, one in which the connected ends of the contacts are hidden or unable to be directly physically accessed, when the connection is made. The electrical connection may be made between device contacts of an electrical device that is inserted into the receptacle, and receptacle electrical contacts that are part of the receptacle. The channels for directing the hot gas to where the soldering occurs may be parts of the receptacle, for example being produced during additive manufacture of the receptacle.