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Empa’s Full X-Ray Study of EURECA Reveals Hidden Damage, Urges Pre- and Post-Flight Checks

The rare returned spacecraft provided an inside view that supports non-destructive inspection to inform reusable design, helping curb debris.

Overview

  • Published in Acta Astronautica in 2025, the study details whole-satellite high-energy X-ray imaging plus targeted component analyses first initiated in 2016.
  • The scans revealed cracks in composite struts, fractures and deformations in scientific instruments, and residues inside the fuel and gas tanks.
  • Researchers employed multi-energy, multi-scale techniques that ranged from the entire carrier structure down to nanometer-level material investigations.
  • Lead author Robert Zboray recommends X-raying reusable satellites before launch and after landing to determine when specific damage occurs.
  • The team says these non-destructive methods could strengthen reusable satellite design, lower orbital debris risk, and carry over to aviation, automotive, and forensic inspections.