Aerodynamics of Re-entry Vehicles on Mars: Balancing Heat Shield Design and Efficiency

Abstract

The design of re-entry vehicles for Mars is one of the toughest challenges in aerospace engineering. It requires careful integration of aerodynamic efficiency and thermal protection. Unlike Earth, Mars has a thin atmosphere made mostly of carbon dioxide. This atmosphere offers limited aerodynamic braking while still generating intense heat during hypersonic entry. This unique environment requires balancing the need to minimize heat shield mass with ensuring enough thermal resilience. Systems that are overdesigned reduce payload capacity, while those that are underdesigned risk mission failure. This paper looks at the aerodynamics of Mars re-entry vehicles, focusing on blunt-body and lifting-body shapes. It analyzes how entry trajectory affects peak heating and total thermal load, showing the trade-offs between shallow and steep descent profiles. The study also reviews thermal protection materials, including phenolic impregnated carbon ablators (PICA), ultra-high temperature ceramics (UHTCs), and new porous carbon ablators that improve radiation scattering. The paper examines innovative design approaches like deployable and inflatable heat shields, hypercone decelerators, and additive manufacturing of thermal protection systems. These methods could boost efficiency and reduce structural mass. Furthermore, it explores aerothermal interactions such as localized heating from surface protrusions and risks linked to boundary-layer transition in flexible shields. These aspects underline the importance of aerodynamic-thermal coupling in designing next-generation systems. By combining advancements in material science, aerodynamic improvement, and deployable designs, this research highlights a comprehensive approach to re-entry vehicle design. The findings suggest that future Mars missions will need hybrid solutions that blend ablative, ceramic, and flexible thermal protection systems to achieve safety and efficiency. Ultimately, achieving this balance will be crucial for reliably delivering larger payloads, supporting robotic missions, and paving the way for human exploration of the Martian surface.