Inflatable heat shields offer new material opportunities and work by reducing the ballistic coefficient for a more gentle (by spacecraft standards) re-entry. Source: IDTechEx

German Start-Up Tests Inflatable Heat Shield in Orbit

Our Bureau - : May 13, 2025 - : 9:07 pm

A German space start-up has completed its first orbital test of a new heat shield concept, potentially marking a shift in how spacecraft may manage atmospheric re-entry in the future. On 22 April, SpaceX’s Bandwagon-3 rideshare mission launched from Cape...

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A German space start-up has completed its first orbital test of a new heat shield concept, potentially marking a shift in how spacecraft may manage atmospheric re-entry in the future.

On 22 April, SpaceX’s Bandwagon-3 rideshare mission launched from Cape Canaveral carrying a variety of payloads—including Phoenix 1, the inaugural test capsule from Germany-based ATMOS Space GmbH. This marked the company’s first orbital trial of an inflatable aerodynamic decelerator (IAD), a technology with the potential to complement or eventually rival traditional re-entry heat shield systems.

Most spacecraft returning from low Earth orbit today rely on either tile-based thermal protection systems (TPS) or ablative materials. Tile-based shields—like those found on the Space Shuttle, X-37, Sierra Space’s Dream Chaser, or SpaceX’s Starship—are designed to absorb and radiate heat away from the spacecraft. Ablators, in contrast, undergo pyrolysis during re-entry, burning away and dispersing heat in the process. These conventional technologies, along with their engineering trade-offs, are examined in detail in IDTechEx’s report “Heat Shields & Thermal Protection Systems for Spacecraft 2025–2035: Technologies and Market Outlook.”

One major constraint with current TPS designs is size—limited by rocket fairing dimensions. IADs, however, present an alternative. Designed to be compact during launch and deployed before re-entry, IADs increase surface area dramatically, reducing the ballistic coefficient and lowering peak heating and mechanical loads. While the concept has been under study for decades, practical implementations have only recently gained momentum.

Differentiation from NASA’s LOFTID

NASA’s 2022 LOFTID mission marked a milestone for IAD research but also revealed key challenges, particularly regarding deployment. LOFTID used a nitrogen inflation system that added 135 kg in tanks and regulators. ATMOS claims to have overcome this hurdle with a different approach: Phoenix 1 used ceramic matrix composite air inlets to harvest atmospheric boundary layer gases for inflation, eliminating the need for pressurised tanks.

This innovation could significantly reduce mass penalties, a critical consideration for space applications. If proven scalable and reliable, the technology could offer a compelling alternative to established re-entry systems.

Materials Landscape and New Opportunities

Traditional TPS materials—such as carbon-carbon composites, silica tiles, and various resin systems—are well-documented and benchmarked in IDTechEx’s report. However, IADs introduce new design requirements that open up possibilities for alternative materials, such as:

Aerogels for lightweight insulation
Ceramic fibres for high-temperature protection
Laminated gas barriers
Braided structural fabrics

Each of these is examined in the IDTechEx report alongside detailed material properties, manufacturing processes, and current supplier activity.
Outcome and Future Plans

Although Phoenix 1 was not recovered after its ocean splashdown over 2,000 km off South America, ATMOS Space confirmed successful data acquisition throughout the mission. The state of the heat shield upon impact remains unknown, but the company has stated it will pursue rapid iteration, with Phoenix 2 already in development. The next mission is expected to feature a propulsion system to enable greater control during re-entry.

ATMOS’s development model reflects an increasingly common philosophy in the space sector, favouring real-world testing and iterative learning—an approach often associated with SpaceX.

Broader Implications for the Space Sector

IADs have the potential to affect several critical areas:

Launch Economics – enabling the recovery of upper-stage components
Planetary Exploration – allowing heavier payloads to land on planets with atmospheres, such as Mars
Defence and Logistics – supporting rapid de-orbiting and re-entry of orbital cargo

Despite being in early development, IADs are beginning to establish a foothold. While established TPS technologies such as PICA and tile-based systems dominate current missions, the space industry’s rapid commercialisation is creating new opportunities. ATMOS’s demonstration—only four years after its founding—illustrates the accelerating pace at which private companies are contributing to spaceflight innovation.

NASA may have led the way with LOFTID, but ATMOS’s differentiated approach, along with ongoing efforts by players such as ULA (which is exploring inflatable decelerators for booster recovery), suggests a broader industry trend. Mechanically deployed aerodynamic decelerators (MDADs) are also being explored as an alternative.

IDTechEx’s “Heat Shields & Thermal Protection Systems for Spacecraft 2025–2035” report provides a comprehensive overview of these technologies, tracking developments, assessing challenges, and evaluating key market players in this evolving landscape.

This article was originally written by Mika Takahashi, Technology Analyst at IDTechEx.

Atmos-space-gmbh / Idtechex / Inflatable-aerodynamic-decelerator-iad / Heat-shield /

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