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Space Capsule Heat Shield Design Challenge | Middle School Engineering Our Cosmos

This unit is part of our new Middle School series, Engineering our Cosmos. Inspired by the true story of NASA heat shield engineer Molly White, whose work on Orion’s thermal protection system is helping to safeguard the astronauts of tomorrow, this STEM unit blends engineering practices and physical science in an engaging design challenge. Drawing from NASA’s Orion mission, students design and build a heat shield to minimize the transfer of thermal energy during reentry to Earth’s atmosphere. Through this engineering design challenge, students explore and apply key science concepts including thermal energy transfer, insulation, and material properties as well as investigate real-world heat shield technologies and STEM careers. The unit also includes developing a mission report to reflect on and present design ideas.

Engineering Our Cosmos Storyline (Adaptable for Grades 6 - 8): Humanity has long looked to the stars with wonder. Now, we stand at the dawn of a new era, where engineers will lead the way to other worlds. Your mission: design the tools, technologies, and systems that enable human exploration and survival beyond Earth. Each challenge brings us closer to life among the stars—and drives innovations that improve life here on Earth. It’s time to start Engineering Our Cosmos!