The interdisciplinary application of experimental and numerical method
s is the crucial strategy for the profound validation of numerical sim
ulations of complex aerothermodynamic hows. Especially for the design
of reusable heat shield materials the reliable re-entry heat flux pred
iction from numerical simulation methods became important. In this con
text free flight measurements gained an outstanding position for the v
alidation of theoretical models describing the high-temperature phenom
ena of thermo-chemically reacting hypersonic flows in interaction with
the flight vehicle's surface. This article is devoted to present a gl
obal concept for the application of a compact free flight sensor expos
ed to the extreme thermal environmental condition of a controlled, bal
listic re-entry. The validation strategy will be demonstrated for tota
l density measurements proposed for the stagnation point of a re-entry
capsule, since the density at the capsule surface reflects sensitivel
y the interaction process of the hot gas and the wall. The partial val
idation of the aerothermodynamic simulation tool was elaborated for la
boratory experiments in the gun-tunnel and shock tube. The measuring p
rinciple of the optical density sensor, the Phase-compensated Michelso
n Interferometer (PMI), will be discussed in detail. Since the feasibi
lity of these measurements are highly dependent on the thermal integra
tion of the sensor, an effective thermal protection concept, based on
modern ceramic matrix composite materials and high performance insulat
ions, has been Verified in numerical analyses.