After the Orion capsule of the Artemis I lunar mission returned to Earth, it was found that massive chunks of its heatshield had been ripped off, posing a serious risk to any future missions. In a recent video in which [polymatt] takes a break from repairing old laptop shells and the like, he tries to recreate the Orion’s heatshield using a variety of methods and materials.

For this test a number of samples were created, each using the same kind of segmented structure as the larger Orion heatshield. The filler was created from the published materials for the heat shield by NASA, requiring just serious mixing.

The resulting samples were then cured with thermocouples inserted, before they got blasted with the heat from a propane torch, trying to simulate the various re-entry patterns.

Perhaps unsurprisingly, the results matched the findings by NASA for why the Orion’s heat shield had failed, being the build-up of gases due to the sustained pyrolysis processes that eventually fractured the material. Despite some experimental flaws that injected residual heat from the copper structure, this still seems to be a pretty good setup to test ablative heat shields in DIY lab conditions.

Perhaps the biggest question going into the Artemis II mission this spring was how the heat shield at the base of the spacecraft would perform during reentry through Earth's atmosphere.

The ablative heat shield, designed to char upon reentry while keeping the crew safe, had experienced unexpected losses of large chunks during a test flight in late 2022. After much deliberation, and not without controversy, NASA decided to fly the Artemis II heat shield as is but modify the spacecraft's reentry trajectory.

Obviously, the heat shield worked. The crew of Artemis II, led by commander Reid Wiseman, safely splashed down in the Pacific Ocean after a triumphant trip around the Moon. Afterward, they and other NASA officials offered general comments, saying the heat shield looked good.

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