A University of Manchester PhD (www.manchester.ac.uk) student has developed a proto-type flexible heat shield for spacecraft that could reduce the cost of space travel.

Heat shields are used as the brakes to stop spacecraft burning up and crashing on entry into a planet’s atmosphere.

The new design is the first in the world to use centrifugal forces that stiffen lightweight materials to prevent burn-up.

Rui Wu from Manchester’s School of Mechanical, Aerospace and Civil Engineering and his team have developed a flexible heat shield that is shaped like a skirt and spins like a sycamore seed.

Planets with atmospheres, such as Earth and Mars, allow spacecraft to use aerodynamic drag to slow down, and the prototype’s design uses this to enable atmospheric entry.

Mr Wu explained: “This is similar to high-board diving, where the drag from water decelerates your body before you reach the bottom of the swimming pool.”

The fast entry into Earth’s atmosphere generates so much heat — over 10,000°C — that the air around the spacecraft can turn into plasma.

For safe atmospheric entry, spacecraft need a shield that tolerates high heat as well as an aerodynamic shape that generates drag.

When entering Earth’s or Mars’ atmospheres, spacecraft require highly designed shields to avoid burn-up, generate drag, and support heavy loads. Wu’s design potentially solves both issues.

The prototype is made of a flexible material that allows for easy storage on board spacecraft. This material, while foldable, is strong and has a high temperature tolerance.

The shield is also stitched along a special pattern that allows it to spin up during flight, inducing centrifugal force.