The return of humans to the Moon under NASA’s Artemis programme is shaping up to be one of the most complex technological challenges of the coming decade. Among the many hurdles, one of the least visible yet most critical lies in materials: their ability to withstand the extreme conditions of space and the intense stress of atmospheric reentry.
As a spacecraft reenters the atmosphere, it faces temperatures exceeding 2,000 °C. Materials must cope with extreme heat, dissipate energy in a controlled way, maintain structural integrity and allow for rapid inspection once back on Earth.
At the heart of this challenge is the heat shield, a key system for crew safety. Today, its outer layer is made of Avcoat, an ablative material that protects the capsule by gradually burning away and carrying heat with it. Originally developed for the Apollo missions in the 1960s and later refined, Avcoat remains a proven solution. Its consumable nature, however, comes at a cost, leading to material loss and limiting the potential for reuse.
Underwater photo of the Orion spacecraft’s heat shield immediately after splashdown on April 11, 2026. NASA
This constraint has intensified global efforts to develop more durable and sustainable alternatives. Among them is CERAM-X (Computationally Engineered Refractories for Additive Manufacturing in eXtreme Environments), led by the Hybrid Materials Laboratory at the Institute of Mechanical Engineering and Materials Technology, positioning itself as a potential step change in how materials for extreme environments are conceived and engineered.
“Rather than starting from chemical composition, CERAM-X engineers performance through the material’s internal geometry,” says Prof. Alberto Ortona. “This approach enables the development of highly controlled porous ceramic structures capable of managing heat, mechanical stress and gas flows more efficiently.”
Improving reusability is a key objective for future missions, with direct implications for cost reduction and environmental impact. “CERAM-X focuses on materials that are not only resistant, but also designed to be easily inspected and reused. It is not just about surviving extreme conditions, but about doing so in a reliable and verifiable way over time,” adds Marco Pelanconi.
Supported by ESA Phi-Lab Switzerland, the European Space Agency’s initiative for high-potential technologies, the project brings together academic expertise and industrial partners including ArianeGroup, Archer Technicoat and EngiCer SA.
“This collaboration combines academic and industrial expertise to accelerate technology transfer towards real applications. The goal is to turn scientific results into concrete solutions for both space and industrial use, with potential impact also in sectors such as energy, transport and high-temperature processes.”
A research effort rooted in materials science, addressing strategic challenges for the future of space exploration and beyond.
Cover image: The Orion crew capsule reenters Earth's atmosphere. NASA