THE CAPSULE that carried Apollo 11 astronauts safely back to Earth in 1969 used a heat shield made of epoxy resin to protect its contents from the 5,000-degree heat of reentry. The resin, called Avcoat, was designed to erode, carrying heat away from the surface. A half century later, NASA’s Orion spacecraft uses the same material. Brian Hinde, Lockheed Martin’s Orion Structures and Aeroshell Senior Manager, says that the most important innovation for heat shield technology isn’t finding new materials, but increasing the efficiency of materials already in use. On the Apollo capsule, the Avcoat was injected into thousands of individual cells of a fiberglass honeycomb, an agonizingly slow process. The tool used was, in essence, “a high-pressure caulk gun,” says Hinde.
For Orion, the caulk gun at least is…