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After the Columbia disaster, NASA engineers had to figure out how astronauts could fix damaged heat shield tiles in space using an adhesive. Astronaut Cady Coleman knew that trying to apply sticky substances in zero gravity would be harder than it looked. So, she brought engineers slices of cake and frosting and asked them to put the cake back together using only the frosting as a simple Earth-based simulation of tile repair in space. The result: a messy, eye-opening challenge that changed how NASA approached space repair tools.
Mission: Reassemble the cake pieces using frosting, but without smashing the parts together
Materials:
· A cupcake or piece of cake broken into several pieces
· Frosting
· Various tool making materials: Masking tape, popsicle sticks, paper
Add a constraint! Wear gloves to simulate spacesuit limitations.
The cupcake should be able to turn each direction (including upside down!) without coming apart
Reflect:
What were the biggest challenges you faced?
What challenges would you face during an EVA?
What seems like a simple task, like spreading frosting on a cake, becomes an unpredictable and surprising engineering challenge in microgravity. That’s why Cady Coleman’s cake experiment was so effective- it gave engineers a memorable way to experience how unruly adhesives can behave beyond Earth!
Glues are surprisingly tricky to apply in the unique, weightless environment of space for several fascinating reasons:
Unpredictable Curing and Bonding
Many adhesives rely on evaporation or chemical reactions to cure—processes that depend on air movement, pressure, and temperature. In space, these conditions are very different. The cabin environment is tightly controlled, with limited airflow and microgravity, which can slow or alter how glues set. Without gravity, the glue doesn’t spread or settle as expected and may float or bead unpredictably.
In space, tools for applying glue need to work without gravity. That means the best tools are ones that can control how much glue comes out and keep it from floating away. Tools like syringes, squeeze tubes, or preloaded cartridges can help push glue out in small amounts. A regular brush or spatula might not work well unless it has grooves or mesh to help trap the sticky material. It also helps if the tools are easy to grip with bulky gloves and can be tethered so they don’t float off.
Design a new way astronauts could apply tile adhesive in space.
How will you contain the adhesive so it doesn’t float away or create a mess?
How can your design control the amount of adhesive and apply it exactly where it’s needed?
How will your tool be easy to use with bulky astronaut gloves and in limited time during an EVA?
Learn how NASA's Orion spacecraft will protect crew on their journey to the moon, Mars, and back home
Learn about new, origami inspired design to protect reusable satellites from high re-entry temperatures
Learn about a new adhesive that is inspired by nature
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