Space Shuttle Challenger Engineering Design Failure + Video

This creative and thought-provoking activity explores one of history’s most significant engineering failures — the Space Shuttle Challenger disaster. This worksheet encourages students to think like engineers by reflecting on the causes, consequences, and lessons learned from real-world engineering decisions.

Students write a postcard reflection as if they were an engineer looking back on the Challenger launch, addressing key prompts such as:

• What went wrong during the launch?
• What could have been done differently?
• What lessons should future engineers and leaders remember?

The activity promotes critical thinking, ethical reasoning, and an understanding of risk management in engineering. A linked YouTube video (included in the resource) provides a short, age-appropriate visual overview to support classroom discussion.

Perfect as a standalone lesson, a cover activity, or an engaging extension task within a broader engineering, design, or science unit.

What’s Included

• Printable postcard-style worksheet (1-page) with a Space Shuttle Challenger case study focus, Reflection prompts for student writing
• Printable foldable postcard alternative.
• YouTube video link for visual context and downloadable video to avoid streaming and other distractions.

Relevant Curriculum Links:

Design & Technology – KS3

• Investigate how products and systems are designed to meet user needs and safety requirements.
• Understand the impact of engineering decisions on people, the environment, and society.
• Evaluate the work of past and present engineers to inform their own ideas.

Engineering – Level 2/3 Vocational Specifications (e.g. BTEC, Cambridge Nationals):

• Unit on Engineering Principles and Processes: understanding causes of engineering failure and the importance of safety checks and material testing.
• Unit on Engineering Product Design and Manufacture: learning from real-world case studies to improve future practice.

Science – KS3:

• Understanding the applications of physics in real-world engineering contexts.
• Recognising the role of scientific evidence and testing in preventing failure.