NASA's planned Artemis II moon mission faces a critical safety crisis. The Orion spacecraft's heat shield, designed for lunar return speeds, suffered severe damage during its 2022 uncrewed test flight. Large chunks of the experimental Avcoat heat shield material spalled off, creating deep gouges and holes.

This spalling exposes the capsule's structure to extreme heat, risks parachute damage from flying debris, and allows hot gas ingestion through melted bolts, potentially causing catastrophic vehicle breakup and crew loss. The agency's initial attempts to downplay the findings and its organizational culture, prioritizing schedule over safety margins, drew sharp criticism. Artemis II's shield was never deemed safe to fly.