Since the past few years, we have been witnessing increasingly fierce competition among various space agencies. According to the report of the United Nations Office for Outer Space Affairs (UNOOSA), more than 4500 man-made satellites orbit the Earth, an increase of 4.87% over the previous years. In addition, the increasing interest in flexible PCBs in satellite applications is attributed to longer life cycles and higher flexibility. The feasibility of a flexible PCB for satellite applications depends on whether the PCB design can operate without faults for up to 10 years.
This has also led to increased competition and several PCB manufacturers playing a role in developing high-end PCBs. Electronic devices need to withstand harsh environmental conditions and maintain quality and reliability performance in space applications. A few years ago, satellite technology was considered an elite field. However, the increasing footprint of relatively small participants globally may increase local competition.
The development of flexible PCBs for satellite applications has attracted great interest from several space agencies. The numerous advantages of flexible technology are the main reasons driving industry participants to adopt flexible PCBs. It is evident that compared to other electronic products and polychlorinated biphenyls, the design and development of space-based commercial satellite products are the most important.
Pay special attention to the design and development of flexible circuit boards to meet the quality and reliability requirements in high-frequency applications. Manufacturers need to ensure that the design of printed circuit boards follows certain requirements in high-frequency applications.
Complexity related to commercial satellite elements
Usually, satellite systems consist of three main circuits, including satellites, receivers, and transmitters. The communication between satellites and transmitters is called uplink, while the communication from receivers to satellites is called downlink. Satellites are increasingly being used for disaster risk management, weather forecasting, remote sensing, geographic positioning, and navigation. Other applications of satellites include television and telecommunications, as well as emergency response monitoring. The electronic components in these circuits are set to cover a height specific wavelength range. These wavelengths are within the Electromagnetic spectrum. The data captured by satellites includes images, atmospheric detection, communication, geographic positioning, and navigation.
The collected information is transmitted over long distances, which is impossible without a ground system that heavily relies on line of sight transmission. Visually speaking, satellites are considered to be used to collect and process information, images, and data from Earth, space, or other satellites. For commercial satellite systems, the satellite itself serves as a relay station, allowing for long-distance data transmission, which is impossible for ground communication systems that rely on line of sight transmission. Commercial satellite systems are divided into three main types based on location, ground equipment, and different services provided.
Satellite type and PCB requirements
Fixed Satellite Service (FSS), Mobile Satellite Service (MSS), and Broadcasting Satellite Service (BSS) are the three main satellite systems used. Fixed Satellite Services (FSS) use fixed receiving stations and provide them to end users. The common applications of Fixed Satellite Services (FSS) include cable television and internet relay stations. Mobile Satellite Services (MSS) handle mobile ground systems and mobile phones. These services are also used for communication between ships and fleet vehicles. Broadcasting Satellite Service (BSS) broadcasts television and radio signals directly to users. For example, Dish Network is used to broadcast television channels to subscribers. Therefore, it becomes crucial for manufacturers to identify challenges and requirements when designing PCBs based on the required applications.
Key factors in Flex PCB design
Important factors that require special attention in the design of Flex PCBs include:
- Temperature change – from -100°C to above 120°
- Maintain track collisions.
- Degassing of hard vacuum limiting materials.
- Ultraviolet (UV) radiation.
- Ionizing radiation.
It is crucial to overcome these challenges while modernizing circuits to reduce space. Commercial satellite components need to be able to withstand harsh conditions during launch and long-term orbit. Flex PCBs manufacturers understand and understand design changes accordingly.
Which aerospace industry standards are applicable for PCB development?
In addition, the number of space agencies is implementing their own commercial satellite product development standards. These standards are specifically used to guide the design and development process of flexible PCBs. In addition, these standards help maintain the quality and reliability of flexible PCB boards. These standards ensure appropriate mechanisms for redesigning, replacing, or recalling fail safe services. The space agency is currently implementing strategic steps that contribute to the integration of support design and high-end development processes. This will further prevent unexpected events in real-time scenarios.
Some common standards followed include:
AS 91000 standard: – Several international organizations, including the International Organization for Standardization (ISO) Aerospace Space technology Committee, the European Aerospace Industry Association (AECMA), and the American Aerospace Quality Group (AAQG) have developed and redesigned the AS9100 standard for the aerospace industry.
IPC, NADCAP, Ministry of Defense, and European Space Agency (ESA) standards: – The aforementioned space agencies have developed their own PCB standards or audit checklists to evaluate manufacturers’ capabilities. These space agencies closely monitor suppliers who have previously demonstrated compliance with standards. These suppliers must meet and maintain minimum audit standards. Some PCB suppliers adhere to the following technical standards to ensure the normal operation of these PCBs.
MIL-STD-55110: – These standards apply to printed circuit boards, rigid, and general specifications.
MIL-PRF-31032: – These standards apply to printed circuit boards/printed circuit boards.
ECSS-Q-ST-70-10C: These standards apply to the qualification of space product assurance and measurement printed circuit boards.
There are more standards to follow.
Materials in Satellite PCB
Ceramics, hydrocarbons, Thermosetting polymer composites developed by Rogers, and Isola, Inc. Manufacturers have been allowed to develop highly reliable satellite PCBs. Most of these materials have dielectric constants (Dk values) ranging from 3.27 to 12.85 on the z-axis. These materials are expected to have a specific set of characteristics. These materials are suitable for challenging operating conditions of orbiting satellites.
Low outgassing is considered one of the main parameters to consider before selecting PCB materials. Degassing is the release of gas from solids, such as PCB materials. Degassing is the release of gas from solids, such as PCB materials. Once released, the gas will condense on different surfaces within the satellite, which may cause problems in certain circuits and subsystems.
The Future Prospects of Satellite PCB Worldwide
Due to the critical task of satellite applications, the development of high-end flexible PCBs has become the primary task for PCB suppliers. It is expected that more and more research and development activities will promote industry growth in the coming years. These satellite PCBs have undergone a series of tests to ensure their consistent performance. More and more private space agencies are expanding the growth opportunities for PCB suppliers in the near future.
The key issues related to flexible PCB design during satellite applications should not be overlooked during the development process. In addition, it is crucial to test and verify the normal operation of the satellite before takeoff. Satellite technology helps make our lives easier and simpler. It’s hard to imagine our modern way of life without it. It is crucial to implement thorough, detailed, and conclusive processes.
So, please continue to pay attention to how the Battle of the Sky will intensify We would like to know what Thor may be considering
