Final Test of the SMS Project for a Future Mission to Mars at CIRA’s Scirocco Plasma Wind Tunnel

Last December, the final test of the SMS (Smart Manufacturing in Space) project was successfully conducted at CIRA’s Scirocco Plasma Wind Tunnel. This milestone represents a crucial step that concludes the Mission and System Study developed over more than one and a half years.

The project was carried out by a consortium comprising CIRA, as lead partner, the Sardinia Aerospace District (DASS), ALI, Lead Tech, the University of Cagliari, and Finis Terrae. The initiative is funded by the Ministry of Research (MUR) under the PON “Research and Innovation” 2014–2020, in line with the PNR 2015–2020.

The objective of the SMS project is the design of a space probe intended for launch in the coming years, subject to launcher availability (ARIANE 62 or VEGA E). The mission aims to manufacture components directly on the Martian surface by exploiting in situ resources, such as regolith, through an innovative powder sintering process.

Throughout the project, CIRA played a central role both as programmatic and technical coordinator and in the development of the main scientific and engineering activities. In particular, CIRA developed the aerodynamic and aerothermodynamic model of the atmospheric entry capsule (AEDB and ATDB), analyzing both the continuum regime and rarefied flow conditions using advanced Direct Simulation Monte Carlo (DSMC – SPARTA) techniques. CIRA also carried out mission and entry trajectory analyses, developed the spacecraft thermo-structural model, and designed and conducted the complex experimental test campaign at the Scirocco facility.

The results of the final test were extremely positive, exceeding initial expectations. The tests enabled the qualification of the thermal shield dome, manufactured using commercial off-the-shelf (COTS) materials and based on the IRENE technology, also developed by CIRA, at temperatures and heat fluxes significantly higher than those expected. This outcome ensures wide safety margins and robustness for a future real mission, confirming the soundness of the adopted technological solutions.