Application of cork in reusable launch systems
Cork-based Thermal Protection System for the Reusable Themis Rocket
Case study on Amorim Cork Solutions’ contribution to Europe’s first reusable rocket demonstrator as part of the SALTO project
Background
In the race to develop sustainable space access, Europe has launched SALTO (reuSable strAtegic space Launcher Technologies & Operations), a Horizon Europe-funded project aimed at validating technologies for reusable launch systems. At the heart of the initiative is Themis, Europe’s first full-scale reusable rocket stage demonstrator, developed by ArianeGroup under the European Space Agency’s Future Launchers Preparatory Program (FLPP).
The SALTO project includes a consortium of 25 partners from 12 countries, covering large aerospace companies, research institutions, and SMEs. Among them is Amorim Cork Solutions, selected for its innovative, sustainable approach to thermal protection.
The Challenge
Design a high-performance, sustainable TPS suitable for modular and reusable configurations.
Reusable launch vehicles experience extreme thermal loads during launch and reentry. These vehicles must be protected by a Thermal Protection System (TPS) that can not only withstand such conditions, but also allow for quick turnaround between missions. Traditional ablative materials often require full replacement, leading to high costs and long refurbishment cycles.
Our Solution
Amorim Cork Solutions developed a bio-based TPS solution made from high-performance cork composites and sustainable resins. Engineered specifically for reusable vehicles like Themis, this TPS is designed to withstand extreme heat while maintaining structural integrity.
To support rapid turnaround, the TPS will be mounted onto modular tiles developed by iDCONCEPTS, allowing for quick removal and replacement after each mission — a key requirement for reusability.
“This approach not only improves thermal performance and structural integrity but also drastically reduces TPS maintenance time,” said Sofia Paixão, Global Technical Manager at Amorim Cork Solutions. “It aligns perfectly with SALTO’s goals of efficiency, environmental responsibility, and reusability.”
Impact
The Amorim Cork Solutions TPS will be tested during Themis’s first hop test — a low-altitude vertical take-off and landing — taking place at the Esrange Space Center in Kiruna, Sweden, operated by the Swedish Space Corporation. This critical milestone will generate key data for future, more complex test flights and marks a major step in Europe’s path toward cost-effective, sustainable space transportation.
Why Cork?
Cork combines unique thermal insulation, impact resistance, and lightweight properties, making it exceptionally well suited for demanding aerospace applications. In the SALTO project, cork-based technology demonstrates its potential as a strategic material for the sustainable evolution of space systems, offering a natural alternative to traditional synthetic solutions.
Results & Outlook
TPS performance validation expected during Themis hop test campaign.
Significant reduction in refurbishment time between flights.
Reinforces cork as a viable material for future reusable launchers.
Positions Amorim Cork Solutions as key players in the new era of European aerospace innovation.
About SALTO project
The ongoing SALTO (Structured Agile Launcher Technology Operations) project, funded through the European Commission’s Horizon Europe program, provides the framework and funding for Themis first stage demonstrator hop test campaign. SALTO supports Europe’s broader ambition to master reusable launch systems by fostering both technological maturity and operational experience through demonstrator platforms like Themis.
The journey of Themis—from design to deployment—represents not only technological innovation but also pan-European collaboration. The project’s consortium involves 25 partners from 12 countries:
- ArianeGroup SAS, ArianeGroup GmbH, MT Aerospace AG, Safran Data Systems, Safran Electronics & Defense, Avio S.p.A., Sabca, Thales Alenia Space Belgium S.A., GTD Sistemas de Información S.A., GMV Aerospace and Defence SA, Deimos Engineering and Systems S.L.U, Sener TAFS SAU, Swedish Space Corporation, Amorim Cork Solutions;
- Research institutes: German Aerospace Center (DLR), CNES, ONERA, IRT Jules Verne, INCAS;
- Start-ups and SMEs: ID-Services, Shark Robotics SARL, G.L.Electronic s.r.o, SIA WIT Berry, Réaltra Space Systems Engineering, SpaceForest sp. z o.o.
This project has received funding from the European Union's Horizon Europe program under grant agreement No 101082007. More information on SALTO project www.salto-project.eu
