Case Study: Dutch Space achieves realistic hypersonic launch and re-entry simulation for EXPERT's metallic TPS with Dassault Systemes (Abaqus)

Dutch Space uses Abaqus to virtually test a new metallic thermal protection system for hypersonic space vehicles

Dutch Space, a Leiden-based supplier of space subsystems, faced the challenge of developing a hybrid thermal protection system (TPS) for the ESA EXPERT re-entry capsule that combined a ceramic matrix composite (CMC) nose with a metallic PM1000 after-body. The two materials have very different thermal expansion (metal ~8× ceramic) and must survive extreme hypersonic heating, vibration and shock without shape changes that would trigger turbulent flow. To minimize costly full-scale testing, Dutch Space selected Dassault Systemes’ Abaqus for high-fidelity virtual testing and design verification.

Using Dassault Systemes’ Abaqus, Dutch Space built unified 3D thermal and structural FE models (integrated with CATIA), mapped CFD heat-flux results from Lore into Abaqus, and ran sequential thermo-mechanical analyses on an HPC cluster. The simulations showed peak temperatures (CMC nose 2165 K, flaps 2328 K, metallic after-body 1464 K), verified gap/step changes and margins of safety within specification, and met a minimum eigenfrequency of 86 Hz. Physical validation tests agreed closely with analysis (bolt joint within 3%, dynamic test within 5%), enabling shorter time-to-market, lower costs and confidence to fly EXPERT without full-scale thermo-mechanical tests.