At the base of Orion are 186 blocks of Avcoat material, individually attached to survive atmospheric reentry. Following Artemis I, analysis revealed the Avcoat was "impermeable," trapping gases and causing cracking. NASA opted to change Orion's reentry profile for Artemis II, utilizing a steeper angle to reduce time in the outgassing environment.

This adjustment largely succeeded but reduced the vehicle's downrange capability from 4,800 nautical miles to 1,775 miles, limiting splashdown site flexibility. For Artemis III and beyond, NASA is switching to a more permeable Avcoat material, which should prevent char loss and restore a larger downrange capability. Meanwhile, the Aerospace Safety Advisory Panel praised NASA's leadership, noting striking comments about their collaboration this year.