Compact Onboard Telemetry System for Real-Time Re-Entry Capsule Monitoring

This paper describes a compact low-cost telemetry system featuring ready-made sensors and an acquisition unit based on the ESP32, which makes use of the LoRa/Wi-Fi wireless standard for communication, and autonomous fallback logging to guarantee data recovery during communication loss. Ensuring safe atmospheric re-entry requires reliable onboard monitoring of capsule conditions during descent. The system is intended for sub-orbital, low-cost educational capsules and experimental atmospheric descent missions rather than full orbital re-entry at hypersonic speeds, where the environmental loads and communication constraints differ significantly. The novelty of this work is the development of a fully self-contained telemetry system that ensures continuous monitoring and fallback logging without external infrastructure, bridging the gap in compact solutions for CubeSat-scale capsules. In contrast to existing approaches built around UAVs or radar, the proposed design is entirely self-contained, lightweight, and tailored to CubeSat-class and academic missions, where costs and infrastructure are limited. Ground test validation consisted of vertical drop tests, wind tunnel runs, and hardware-in-the-loop simulations. In addition, high-temperature thermal cycling tests were performed to assess system reliability under rapid temperature transitions between −20 °C and +110 °C, confirming stable operation and data integrity under thermal stress. Results showed over 95% real-time packet success with full data recovery in blackout events, while acceleration profiling confirmed resilience to peak decelerations of ~9 g. To complement telemetry, the TeleCapsNet dataset was introduced, facilitating a CNN recognition of descent states via 87% mean Average Precision, and an F1-score of 0.82, which attests to feasibility under constrained computational power. The novelty of this work is twofold: having reliable dual-path telemetry in real-time with full post-mission recovery and producing a scalable platform that explicitly addresses the lack of compact, infrastructure-independent proposals found in the existing literature. Results show an independent and cost-effective system for small re-entry capsule experimenters with reliable data integrity (without external infrastructure). Future work will explore AI systems deployment as a means to prolong the onboard autonomy, as well as to broaden the applicability of the presented approach into academic and low-resource re- entry investigations.