Space missions demand uncompromising reliability, precision, and durability, especially when it comes to onboard electronic systems aside from spacecraft hardware. From satellites to rovers to crewed spacecraft, the need for lightweight, durable, and efficient circuit solutions has never been greater. This is where high-reliability flexible circuits come into play.
Flexible printed circuits (FPCs) play an important role in modern space electronics due to their ability to reduce weight, save space, and endure extreme environmental stress. The lighter the weight of the spacecraft, the longer it will orbit in outer space or around a planet. A spacecraft, even an unmanned one, carries various equipment installed onto it, such as cameras, sensing systems, rovers, soil testing devices, and more. All of these involve electronics that must be lightweight. Hence, there’s a high demand for flexible electronics in this sector. This post explores the critical role that flex circuits play in space applications and why leading space organizations trust them for mission-critical systems.
The Weight Factor: Reducing Mass in Spacecraft Design
Every gram matters in aerospace engineering. Launching spacecraft into outer space is an energy-intensive process that happens after orbiting around the earth before propelling out of gravity into outer space. Even changing its trajectory with all the systems and components becomes energy and fuel-intensive. This is why even a slight reduction in weight can translate to significant cost savings and improved performance. That’s why engineers meticulously evaluate every component for its mass efficiency, including the electronic circuitry.
Flexible PCBs offer a major advantage in this regard. They are made with thin, lightweight substrates like polyimide, allowing them to dramatically reduce the overall weight of electronic assemblies. By integrating multiple circuit paths into a single, lightweight layer, they eliminate the need for heavy connectors and cables.
Compact Solutions: Space-Saving and Complex Geometries
In a spacecraft design, space is at a premium. Every square inch of internal volume must be used efficiently to accommodate intricate systems like navigation controls, communication modules, sensors, and power distribution modules. Flexible boards solve this challenge by adapting to complex 3D configurations with ease. Their bendable and foldable structure allows them to conform to tight contours, wrap around curves, and fit into irregularly shaped compartments. This makes them ideal for applications where circuit routing through narrow or crowded enclosures is necessary.
Withstanding Harsh Space Conditions
The space environment is among the most extreme and unforgiving imaginable. From intense vibration during launch to drastic temperature swings and radiation exposure, electronic components must be engineered to survive and perform flawlessly. They may even be exposed to solar storms. This is where high-reliability flex circuits prove their exceptional value.
They are designed to endure the mechanical and thermal stresses of space missions. Their materials like polyimide or polyester substrates and light metallic coating are inherently resistant to both high heat and extreme cold, often tolerating temperatures ranging from -200°C to +200°C. This makes them ideal for operating in the vacuum of space, where traditional materials would become brittle or fail.
Long-term Durability and Reliability of Flexible PCBs Space missions often span years without the possibility of repair or maintenance. In such cases, long-term durability and reliability are a must. Some self-repairing materials may also be used. This is yet another area where high-reliability flex circuits shine. Here’s why:
- Flex boards have fewer solder joints, connectors, and mechanical interfaces, all common points of failure over time. This streamlined design drastically reduces the likelihood of electrical faults due to thermal cycling, vibration fatigue, or mechanical wear.
- Material used in aerospace-grade flex PCBs such as polyimide or polyester are selected for their resistance to aging, moisture, UV exposure, and chemical outgassing. These materials help maintain circuit integrity even after prolonged exposure to the harsh conditions of space.
- Flex circuits also support high-cycle flexing, making them ideal for applications involving moving parts, like solar panel arrays or robotic arms. Their consistent performance over millions of cycles ensures reliability in dynamic environments where traditional circuits would fail.
Why Aerospace Engineers Trust Rigiflex
Rigiflex’s state-of-the-art manufacturing facility in Anaheim, California, is equipped to handle complex PCB designs and manufacturing projects with precision and efficiency. They find use even in mission-critical space applications. The company manufactures lightweight PCBs with layer counts ranging from 1 to 24+, accommodating various design complexities. They are capable of achieving fine trace/space dimensions down to .003”/.003” and drilled holes as small as .004”, enabling compact and intricate designs.
From enduring launch vibrations and thermal fluctuations to fitting seamlessly into compact, complex spacecraft designs, These flex PCB assemblies are a cornerstone of modern aerospace engineering. Rigiflex can be your trusted partner with the expertise, certifications, and capabilities to deliver precision-engineered flexible circuits tailored for aerospace and defense applications. If you are ready to launch your next project, feel free to call their team today to explore custom flex PCB solutions for your aerospace needs.
