How Flexible PCBs Can Be Used in Space Applications
Flexible PCBs Can Be Used in Space Applications
One of the key concerns with PCBs used in space is their ability to withstand dynamic forces. These can cause vibrations that can damage tracks, break joints or cause the PCB to delaminate. Flexible PCBs are built to twist and bend in extreme operating conditions like these, allowing them to continue to operate reliably in harsh environments.
The PCBs used in satellite applications must be able to withstand a great deal of pressure during liftoff and during long-term orbits, and flex circuit boards are the ideal choice. PCBWay has helped many customers redesign their products using flex PCBs to reduce the overall weight of the product. They are also much thinner and take up less space than rigid PCBs, making them ideal for tight spaces. Typically, flex PCBs are made from a flexible material like polyimide. Conductors are etched into the layers of this flexible substrate, and the final PCB is covered in a protective coverlay to keep out moisture and dirt.
While it may seem counterintuitive to use a flex circuit board in a space application, the reality is that the weight of all components in a product adds up, and reducing the size and weight of a PCB can make a significant difference. Spacecrafts experience a lot of gravity during liftoff, and a flex PCB can significantly lower the mass of the product, cutting down on fuel consumption and the amount of energy needed to propel the vehicle into space.
How Flexible PCBs Can Be Used in Space Applications
In addition to their flexibility, flex PCBs offer superior resistance to vibrations that can disrupt a device’s operation. They can also be routed at tough angles, which is especially important in satellite applications where a device will have to work in an extremely constrained environment with limited space.
The copper that is etched into the layers of the flex circuit board is annealed to improve its fatigue resistance, which is critical for any PCB that will be bending and stretching all the time. This is why it’s better to use rolled annealed copper rather than un-annealed copper for flex circuits. The annealing process elongates the grain structure of the copper, which makes it more springy in the Z direction.
A flex circuit can be designed to include different sections that are connected by solder joints. It can also incorporate vias, which are small holes that connect the different layers of the flex circuit. This is essential for transferring electricity through the PCB and connecting to other devices in the system.
In order to ensure the reliability of a flex circuit, it’s important to work with an experienced supplier. Pioneer Circuits was a proud partner of NASA/JPL on their Curiosity Rover mission, providing the flex circuitry that enabled the rover to outlast its 2-year-long journey on Mars. In addition, our flex has been used in the Deep Space Network (DSN), which performs radio and radar astronomy observations for interplanetary exploration. We have also worked on Cube Sats (small satellites) that are being launched for space exploration.