NASA is testing heat shields that can keep astronauts safe as they return from missions to the Moon and Mars in an unusual way: by taking out the trash.

When Northrop Grumman 24^th cargo resupply mission for NASA undocked from the International Space Station, it carried a fleet of 12 small, experimental capsules designed to test the next generation of thermal protection materials that could serve as the foundation for future heat shields.

The experiment, called the Kentucky Reentry Probe Experiment (KREPE-3), is the third in a series of low-cost, high-impact missions that use the final moments of the cargo spacecraft’s lifespan to gather valuable data.

The experiment is a collaboration among the University of Kentucky, the state of Kentucky, NASA’s Established Program to Stimulate Competitive Research (EPSCoR), several NASA centers, and other federal and commercial partners.

“KREPE-3 is a great example of the goals of NASA’s EPSCoR program,” said David Berger, EPSCoR program manager at NASA’s Headquarters in Washington. “We are supporting the next generation of scientists and engineers as they develop unique projects that benefit their education and NASA’s mission goals.”

Trash to treasure

Before the mission’s Cygnus XL spacecraft departed the station, astronauts packed it with waste and activated the 12 small capsules carried inside. Designed by University of Kentucky students, the capsules include sensors that will measure temperature, pressure, motion, magnetic field, and light during re-entry. 

As the vehicle harmlessly breaks apart in Earth’s atmosphere on its planned route, the capsules will eject and begin collecting data on how each set of experimental heat shield materials performs. Satellite signals will transfer live data to researchers, offering insights into how larger heat shields could protect future cargo or crew.

“It’s a smart way to get flight data on materials that are still in development,” said Keith Peterson, a materials engineer at NASA’s Ames Research Center in California’s Silicon Valley. “We’re essentially hitching a ride on a vehicle that’s already coming back to Earth.”

Heating up innovation

The capsules will carry a variety of thermal protective components, including proven technology such as the ceramic tile material used on the space shuttle. Others will test new options, such as a 3D-printed heat shield from the Additive Manufacturing of Thermal Protective Systems project developed at NASA Johnson and Oak Ridge National Laboratory.

Researchers at NASA Ames are contributing several materials to KREPE-3, including two capsules that will fly a next-generation family of protective coverings known as Materials Engineered for Re-entry using Innovative Needling Operations (MERINO). Made from layers of carbon and phenolic fibers stitched together like felt, the materials are more flexible, faster to produce, and less expensive than traditional protective substances – making them promising candidates for Mars missions. Thanks to Mars’ thinner atmosphere, missions to land on the Red Planet involve lower heat loads and allow for lighter protection.

A third capsule will combine those protective coverings with other elements. The Kentucky Instrumented Conical Hypersonic Experiment will utilize a dual-cone shape. It combines a tungsten tip attached to a cone layered with carbon and hear-resistant plastic fibers, and an aft cone wrapped in MERINO. This unique design will validate computer models against real-world data.

Another capsule is shaped like the protective aeroshell that will protect NASA’s upcoming mission, Dragonfly, as it arrives at Saturn’s moon, Titan, and will test the dynamic stability of the design. It is covered in Phenolic Impregnated Carbon Ablator, a material developed at NASA Ames that has applications for commercial vehicles and flew on NASA’s Stardust, Mars Science Laboratory, and Mars 2020 missions.

One capsule will test a deployable heat shield called Adaptable Deployable Entry and Placement Technology, which is shaped like an umbrella to increase surface area and slow descent. At full scale, Adaptable Deployable Entry design could be folded, making it ideal for deploying payloads that are larger than the rockets that launch them into flight.

While some capsules are testing new materials to carry missions to Mars, others are testing new shapes and designs that will further research and understanding of computer modeling and sensor design — technologies that could open doors to another generation of re-entry design innovation.

Additional capsules developed by domestic and international partners will test a variety of known and new materials, including a heat flux sensor developed at the University of Stuttgart in Germany, that will help researchers measure how heat moves across a surface during re-entry.

“We’re pushing the boundaries of what heat shields can do,” said Peterson. “And we’re testing them in a way that’s fast, affordable, and incredibly effective.”

NASA is testing heat shields that can keep astronauts safe as they return from missions to the Moon and Mars in an unusual way: by taking out the trash.

When Northrop Grumman 24^th cargo resupply mission for NASA undocked from the International Space Station, it carried a fleet of 12 small, experimental capsules designed to test the next generation of thermal protection materials that could serve as the foundation for future heat shields.

The experiment, called the Kentucky Reentry Probe Experiment (KREPE-3), is the third in a series of low-cost, high-impact missions that use the final moments of the cargo spacecraft’s lifespan to gather valuable data.

The experiment is a collaboration among the University of Kentucky, the state of Kentucky, NASA’s Established Program to Stimulate Competitive Research (EPSCoR), several NASA centers, and other federal and commercial partners.

“KREPE-3 is a great example of the goals of NASA’s EPSCoR program,” said David Berger, EPSCoR program manager at NASA’s Headquarters in Washington. “We are supporting the next generation of scientists and engineers as they develop unique projects that benefit their education and NASA’s mission goals.”

Trash to treasure

Before the mission’s Cygnus XL spacecraft departed the station, astronauts packed it with waste and activated the 12 small capsules carried inside. Designed by University of Kentucky students, the capsules include sensors that will measure temperature, pressure, motion, magnetic field, and light during re-entry. 

As the vehicle harmlessly breaks apart in Earth’s atmosphere on its planned route, the capsules will eject and begin collecting data on how each set of experimental heat shield materials performs. Satellite signals will transfer live data to researchers, offering insights into how larger heat shields could protect future cargo or crew.

“It’s a smart way to get flight data on materials that are still in development,” said Keith Peterson, a materials engineer at NASA’s Ames Research Center in California’s Silicon Valley. “We’re essentially hitching a ride on a vehicle that’s already coming back to Earth.”

Heating up innovation

The capsules will carry a variety of thermal protective components, including proven technology such as the ceramic tile material used on the space shuttle. Others will test new options, such as a 3D-printed heat shield from the Additive Manufacturing of Thermal Protective Systems project developed at NASA Johnson and Oak Ridge National Laboratory.

Researchers at NASA Ames are contributing several materials to KREPE-3, including two capsules that will fly a next-generation family of protective coverings known as Materials Engineered for Re-entry using Innovative Needling Operations (MERINO). Made from layers of carbon and phenolic fibers stitched together like felt, the materials are more flexible, faster to produce, and less expensive than traditional protective substances – making them promising candidates for Mars missions. Thanks to Mars’ thinner atmosphere, missions to land on the Red Planet involve lower heat loads and allow for lighter protection.

A third capsule will combine those protective coverings with other elements. The Kentucky Instrumented Conical Hypersonic Experiment will utilize a dual-cone shape. It combines a tungsten tip attached to a cone layered with carbon and hear-resistant plastic fibers, and an aft cone wrapped in MERINO. This unique design will validate computer models against real-world data.

Another capsule is shaped like the protective aeroshell that will protect NASA’s upcoming mission, Dragonfly, as it arrives at Saturn’s moon, Titan, and will test the dynamic stability of the design. It is covered in Phenolic Impregnated Carbon Ablator, a material developed at NASA Ames that has applications for commercial vehicles and flew on NASA’s Stardust, Mars Science Laboratory, and Mars 2020 missions.

One capsule will test a deployable heat shield called Adaptable Deployable Entry and Placement Technology, which is shaped like an umbrella to increase surface area and slow descent. At full scale, Adaptable Deployable Entry design could be folded, making it ideal for deploying payloads that are larger than the rockets that launch them into flight.

While some capsules are testing new materials to carry missions to Mars, others are testing new shapes and designs that will further research and understanding of computer modeling and sensor design — technologies that could open doors to another generation of re-entry design innovation.

Additional capsules developed by domestic and international partners will test a variety of known and new materials, including a heat flux sensor developed at the University of Stuttgart in Germany, that will help researchers measure how heat moves across a surface during re-entry.

“We’re pushing the boundaries of what heat shields can do,” said Peterson. “And we’re testing them in a way that’s fast, affordable, and incredibly effective.”

NASA’s researchers know that when you settle into your seat on a commercial flight, you expect a smooth takeoff, views over the clouds, a steady descent, and hopefully an early arrival at your destination. But when your flight gets delayed on the tarmac instead of lifting off, or it ends up in a holding pattern rather than landing on time, things start to change. Your experience goes from smooth to anxiety-inducing as you worry about making your connection or getting home in time for dinner.

Large airports are among the busiest, most complex environments in aviation, with aircraft, ground crews, and service vehicles sharing crowded taxiways. Researchers at NASA’s Ames Research Center in California’s Silicon Valley recently worked with Boeing to advance three types of field tests – digital taxi information, safe taxiway, and safe runways – that could lead to safer, more efficient runway environments at airports.

During the digital taxi tests, pilots were given taxiway guidance directly on cockpit displays or tablets, instead of verbally from air traffic controllers. Aircraft autonomously followed digital routes while researchers monitored a suite of sensors designed to identify vehicles or other aircraft impeding the taxi path and runway. The system reduced pilot and air traffic controller workloads and the risk of verbal errors.  

Safe runway technology testing can also improve situational awareness for approaching aircraft. While preparing to land a Boeing aircraft during testing, the same sensors successfully flagged a vehicle on the runway, providing additional awareness to ensure pilots could avoid potential collisions or other safety concerns.

Together, these NASA capabilities aim to reduce miscommunication, ease pilot workloads, and keep airport traffic moving smoothly. Future testing will integrate the sensor and digital taxi systems into a simulated air traffic control environment to evaluate how the technologies can benefit overall management of the airspace.

For years, NASA has worked to improve your experience when flying by developing new technologies to modernize the commercial airline system. Key NASA technologies streamline and digitize the flying experience – from the departure gate, to the skies, to your safe arrival at your destination.

“Aviation safety is key to NASA’s research,” said Parimal Kopardekar, director of NASA’s Airspace Operations and Safety project. “Technology that can provide additional autonomy and support a future airspace with multiple aircraft operating in harmony is key to advancing the National Airspace System.”

NASA’s research innovations continue after your flight takes off. Modern flights constantly respond to shifting weather, turbulence, and traffic. Even small changes in direction or altitude can affect when a plane arrives. These changes can force flights into holding patterns while air traffic controllers attempt to rebalance the busy airspace.

NASA’s air traffic management researchers have been working for years to reduce those situations. In a 2025 collaborative effort with Boeing, United Airlines, and international partners, NASA evaluated real‑time trajectory sharing on domestic and transoceanic flights.

During that testing, a United Airlines Boeing 737 aircraft shared frequent flight information with airline operations centers and air traffic control. NASA used the data to understand how frequently those updates should be sent and what details matter most for generating accurate arrival predictions. Better information helps controllers sequence traffic more precisely, which means fewer holding patterns and more direct descents for passengers.

Pre-departure rerouting technology and digital exchange tools developed at NASA allow dispatchers and controllers to see the same digital picture of flights preparing to depart.

When a better route becomes available, controllers could coordinate the change digitally instead of relying on verbal communication between pilots, controllers, and dispatchers. The technology could lead to fewer delays, reduced fuel consumption, and more predictable operations for passengers.

NASA has now transferred the routing technology to the Federal Aviation Administration (FAA) and airlines will continue to test it. These tools build on decades of NASA contributions to national airspace modernization.

In coordination with the FAA, NASA has advanced automation concepts, improved how arrival and departure flows are managed, and introduced data‑driven software that commercial airlines use every day.

By working closely with airlines, manufacturers, and global partners, NASA is helping to improve every phase of flight to make air travel safer and more reliable, now and in the future.