PCB Tech - What is the flexible PCB in satellite applications?

Since the past few years, we are witnessing increasingly fierce competition among various space agencies. According to a report by the United Nations Office for Outer Space Affairs (UNOOSA), more than 4,500 artificial satellites orbit the earth, an increase of 4.87% compared to previous years. In addition, the interest of flexible PCBs in satellite applications is increasing due to longer life cycles and greater flexibility. The feasibility of flexible PCBs for satellite applications depends on whether the PCB design can operate without failure for up to 10 years.

This has also led to increased competition and several PCB manufacturers playing a role in the development of high-end PCBs. Electronic equipment needs 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 global footprint of relatively small players may increase local competition.

The development of flexible PCBs for satellite applications has aroused great interest in several space agencies. The many advantages of flexible technology are the main reasons that promote the adoption of flexible PCBs by industry participants. Obviously, compared with other electronic products and PCBs, the design and development of space-based commercial satellite products is the most important.

Pay special attention to the design and development of flexible circuit boards to meet the quality and reliability in high-frequency applications. The manufacturer needs to ensure that the design of the printed circuit board follows certain requirements in high frequency applications.

Complexity associated with commercial satellite elements

What is the flexible PCB in satellite applications?

Generally, a satellite system consists of three main circuits, including a satellite, a receiver, and a transmitter. The communication between the satellite and the transmitter is called the uplink, and the communication from the receiver to the satellite is called the downlink. Satellites are increasingly used for disaster risk management, weather forecasting, remote sensing, geolocation and navigation. Other applications of satellites include television and telecommunications and emergency response monitoring. The electronic components in these circuits are set to cover a highly specific wavelength range. These wavelength ranges are within the electromagnetic spectrum. The data captured by satellites includes imagery, atmospheric sounding, communications, geolocation and navigation.

The collected information is transmitted over a long distance, which is impossible if there is no ground system that relies heavily on line-of-sight transmission. Figuratively speaking, satellites are regarded as used to collect and process information, images and data from the earth, space or other satellites. For commercial satellite systems, the satellite itself serves as a relay station, allowing long-distance data transmission, which is impossible for terrestrial communication systems that rely on line-of-sight transmission. Commercial satellite systems are divided into three main types according to location, ground equipment and different services provided.

Satellite type and PCB requirements

Fixed Satellite Service (FSS), Mobile Satellite Service (MSS) and Broadcast Satellite Service (BSS) are the three main satellite systems used. Fixed satellite service (FSS) uses fixed receiving stations and is provided to end users. Common applications of fixed satellite service (FSS) include cable television and Internet relay stations. Mobile Satellite Service (MSS) deals with mobile terrestrial systems and mobile phones. These services are also used for communication between ships and fleet vehicles. Broadcast Satellite Service (BSS) broadcasts TV and radio signals directly to users. For example, Dish Network is used to broadcast TV channels to subscribers. Therefore, it is critical for manufacturers to identify challenges and requirements when designing PCBs for the desired application.

The key factors of Flex PCB design

Important factors that need special attention in the design of Flex PCBs include:

Temperature change-from -100°C to over 120°C.

Maintain orbital collision.

The hard vacuum limits the outgassing of the material.

Ultraviolet (UV) radiation.

ionizing radiation.

It is critical to overcome these challenges while modernizing the circuit to reduce space. Commercial satellite components need to be able to withstand the harsh conditions during launch and long-term orbits. Flex PCBs manufacturers understand and understand design changes accordingly.

Which aerospace industry standards apply to 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 flexible PCB design and development process. In addition, these standards help maintain the quality and reliability of flexible PCB boards. These standards ensure proper mechanisms for fail-safe services such as redesign, replacement or recall. The space agency is currently implementing strategic steps that will help to incorporate safeguard design and high-end development processes. This will further prevent unexpected events in real-time scenarios.

Some common standards followed include:

AS 91000 standards:-Many international organizations including the International Organization for Standardization (ISO) Aerospace Technical Committee, the European Aerospace Industry Association (AECMA), and the American Aerospace Quality Group (AAQG) have developed and redesigned for the aerospace industry The AS9100 standard.

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 assess the capabilities of manufacturers. These space agencies closely monitor suppliers who have previously proven compliance with the standards. These suppliers must meet and maintain minimum audit standards. Some PCB suppliers comply with the following technical standards to ensure the normal operation of these PCBs.

MIL-STD-55110:-These standards apply to printed circuit boards, rigid, general specifications.

MIL-PRF-31032:-These standards apply to printed circuit boards/printed circuit boards.

ECSS-Q-ST-70-10C:-These standards apply to space product assurance and measurement of printed circuit board qualifications.

There are more standards to follow.

Materials in satellite PCB

Ceramics, hydrocarbons, thermoset polymer composites developed by Rogers Corporation, and Isola, Inc. Manufacturers have been allowed to develop highly reliable satellite PCBs. Most of these materials have a dielectric constant (Dk value) of 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 the challenging operating conditions of orbiting satellites.

Low outgassing is considered to be one of the main parameters that need to be considered before selecting PCB materials. Degassing is the release of gas in solids, such as PCB materials. Degassing is the release of gas in solids, such as PCB materials. Once released, the gas will condense on different surfaces within the satellite, which may cause problems with certain circuits and subsystems.

Satellite PCB's future prospects worldwide

Due to the critical task of satellite applications, the development of high-end flexible PCBs has become the primary task of PCB suppliers. It is expected that more and more research and development activities will promote industry growth in the coming years. These satellite PCBs undergo a series of tests to ensure their consistent performance. More and more private space agencies are expanding the growth opportunities of PCB suppliers in the near future.

The criticality related to flexible PCB design during satellite applications should not tolerate errors during the development process. In addition, it is very important to test and verify the normal operation of the satellite before takeoff. Satellite technology helps to make our lives easier and simpler. It is hard to imagine a modern lifestyle without it. It is essential to implement a thorough, detailed and conclusive process.