ESA Project SHIELD advances reusable spacecraft

Oxy-acetylene torch test performed on Arceon’s Carbeon composite materials. Source (All Images) | Arceon

A cross‑European consortium has announced the development of SHIELD, an advanced thermal protection system (TPS) designed to meet the stringent demands of reusable space transportation. The project addresses two critical mission profiles — low Earth orbit (LEO) operations and high‑energy reentry scenarios — offering next‑generation performance through innovative materials and interface designs.

For strenuous reentry regimes, consortium member Arceon (Delft, Netherlands) will deploy its high-performance variant of Carbeon (C/C-SiC) composite panels, ensuring thermal resilience, reusability, durability, scalability and affordability.

Carbeon leading edge is tested 100 millimeters (3.93 inches) away from the solid rocket motor exit.

In order to streamline TPS maintenance and reduce lifecycle costs, Project SHIELD will feature reversible and reconnectable interface systems, enabling rapid assembly, inspection and replacement without sacrificing structural integrity, thus significantly increasing efficiency for reusable spacecraft.

This initiative is a part of the European Space Agency’s (ESA) FIRST! Reusability call under the Future Launchers Preparatory Programme (FLPP), which targets transformative TPS, descent and interface technologies. Notably, the Orbital Paradigm consortium — partnering with Arceon, Von Karman Institute (VKI) and Sirius Space Services — has been selected to advance descent systems and thermal protection technologies

ESA FIRST!

The ESA announced eight new development projects selected through FLPP, its program for future space transportation, and its FIRST! initiative, at Paris Air Show 2025. The initial project call “attracted 27 proposals from 11 countries, with more than half submitted by consortia — 10 of them international,” as reported by the ESA.

“Working with FIRST! has enabled us to mature our technology for cryotanks through a fast and efficient process, reaching the stage where we include end-users in our activities for future commercialization,” said Robin Trigueira, CTO & Co-founder, CompPair Technologies Ltd, one of the selected companies under FIRST! Reusability. “We are looking forward to the next year of this project and reaching a crucial milestone in breadboard building for reusable structures in the space industry.”

The FIRST! Reusability Invitation to Tender (ITT) covered four focus areas critical to reusable launch systems, with two contracts awarded in each category:

Technologies for Refurbishment and Operations

Almatech in consortium with CSEM
CompPair Technologies in consortium with Invent

Landing and Recovery Systems and Technologies

5M s.r.o. in consortium with L.K. Engineering, s.r.o. and VZLU Aerospace
GMV Innovating Solutions (PL)

Reversible/Reconnectable Interface Systems and Technologies

deltaVision GmbH in consortium with Airbus Defence and Space GmbH, OHB System AG and InSpacePropulsion Technologies GmbH
Occam Space

Descent Systems and Technologies (including thermal protection and management)

Orbital Paradigm in consortium with Arceon, Von Karman Institute for Fluid Dynamics and Sirius Space Services
University of Twente in consortium with Royal Netherlands Aerospace Centre (NLR) and Technische Universitat Dresden

Each project has a 12-month contract with the ESA, with results expected to be presented at the FLPP Autumn Session in 2026. Projects supported by FIRST! typically reach TRL 4-5, delivering tested components that can support the development of reusable space systems for future missions.