The rapid development of space economy is posing big challenges, a major one being space debris mitigation. Under this respect, the Horizon Europe EARS project aims to introduce the disruptive concept of reusability in the SmallSat market, taking a step towards a more sustainable exploitation of space. EARS main objective has been to outline the concept of operations (CONOPS) of a small reusable satellite and the maturation of the relevant key enabling technologies needed to guarantee a safe re-entry to the satellite and its payload. In this paper, we present the preliminary design of the EARS spacecraft, its CONOPS and mission engineering with an overview of the simulations conducted to assess the aerodynamic load during spacecraft re-entry and the Plasmatron tests executed for the selection and characterization of the materials suitable for the construction of an inflatable thermal protection system to guarantee a safe atmospheric re-entry.