Core Benefits for Next-Gen Constellations

Satellite manufacturing isn’t what it was just a few years ago – 

Innovation has accelerated dramatically, shifting the focus from lower-volume research & development builds to high-volume, repeatable manufacturing for large satellite constellations.

However, the demand for highly performance thermal management materials capable of surviving the harsh temperatures of space remains, even in this new high-speed environment of rapid iteration and mass production.

The long and the short of it is this: Satellite constellation manufacturers need highly engineered thermal management materials that don’t fail in orbit and are easy to customize, assemble, and integrate quickly into assembly lines.

Enter flexible graphite…

Flexible graphite checks both of these boxes — It’s a lightweight, mechanically stable heat spreader, and it can be easily die-cut, converted, integrated with adhesive backings, pull tabs, and other helpful assembly aids that make production & handling more efficient.

Today, we’re highlighting three innovative flexible graphite materials from NeoGraf’s eGraf® family of products: 

• HiTherm™ - This flexible graphite Thermal Interface Material (TIM) boasts a high Z-directional thermal conductivity. The material doesn’t outgas, dry out, creep, or wear out and can be reworked if needed. Available thicknesses: 127µm to 510µm, Z-directional thermal conductivity ratings: 10 W/m‧K. 
• SpreaderShield™ - Flexible graphite heat spreaders that are used to cool hot components, reduce surface hot spots, reduce thermal gradients, and shield temperature-sensitive components. Designed to flex continuously without damage, this graphite is ideal for thermal straps or thermal radiators. Available thicknesses: 40µm to 940, Thermal conductivity ratings: 400 to 600 W/m‧K, respectively.  
• NeoNxGen™ - NeoNxGen™ is a high-performance heat-spreading material designed for applications that demand very high thermal transfer in a thin and lightweight form factor. With the highest heat-spreading-to-mass ratio of any commercial product, NeoNxGen is ideal for spacecraft thermal radiators. Available thicknesses: 280µm to 500 µm, Thermal conductivity rating: 1000 W/m‧K. 

For more info on NeoGraf’s eGraf® family, check out this eGraf® Flexible Graphite Q&A! 

Applications of Flexible Graphite in Space

How is graphite used in satellite constellation manufacturing?

Before we jump into the benefits, it’s important to know how satellite manufacturers use flexible graphite. Each of these applications benefits from graphite's lightweight nature, lack of outgassing, and durability. 

Thermal Radiators

Since heat cannot leave the spacecraft by convection, it must first be conducted away from the source and then radiated into space. With their high thermal conductivity and low mass, NeoNxGen and SpreaderShield are ideal materials for satellite thermal radiator applications. 

Thermal Interfaces

Transferring heat from a hot surface to a cold surface requires a Thermal Interface Material (TIM). This is especially true in space, where micro-areas of vacuum between hot and cold plates result in poor heat transfer. HiTherm is a high-performance TIM that is lightweight, non-outgassing, and never wears out. It is listed in the NASA outgassing database for use in spacecraft. 

Thermal Straps

Thermal straps are used to efficiently transfer heat between parts of a satellite. These straps are multilayer stacks of SpreaderShield or NeoNxGen flexible graphite, with compression fixtures on either end. The straps are then thermally attached to the spacecraft using HiTherm HT-1205 flexible graphite TIM.

 5 Benefits of eGraf® Materials in Satellite Manufacturing

Now, we’ll be taking a look at 5 key benefits of these die-cut materials in the context of high-volume satellite constellation manufacturing. 

Flexible graphite’s anisotropic thermal conductivity allows it to spread heat efficiently in-plane across broad satellite surfaces, preventing localized hot spots and helping cool hot components. 

 

 2. Lightweight 

Compared to other heat spreaders, like copper and aluminum, Graphite is much less dense with the same or better thermal conductivity. When compared specifically to copper, graphite is over 80% lighter! Lightweight graphite spreaders support overall mass reduction, preserve payload capacity, and enable compact designs, all without sacrificing heat spreading performance.  

 

3. Low-Outgassing 

Flexible graphite is an inorganic, carbon-based material, making it inherently low-outgassing when exposed to the vacuum of space. This prevents the risk of volatile compounds or material deposits interfering with optical sensors, electronics, or other mission-critical equipment.

 

4. Lack of Mechanical Aging & Minimal Compression 

Unlike other polymer-based thermal pads or foams, flexible graphite is not prone to mechanical aging, hardening, or significant compression. eGraf® material maintains stable thickness, contact, and heat-spreading performance throughout repeated thermal cycling and long missions. 

Did you know? NeoGraf HiTherm™ HT-1205 was used to solve a thermal challenge on the International Space Station! Because HiTherm doesn’t outgas or wear out, it’s the perfect solution for long-term space TIM (thermal interface material) challenges and will remain functional for the life of the spacecraft.

 

5. Converting/Assembly Friendly 

Thin, flexible, and sourced in roll form, eGraf® materials are the perfect candidate for custom die-cutting and converting! While impressive on their own, you need a vertically integrated flexible materials converter (like JBC!) to be able to turn raw flexible graphite materials into assembly-ready satellite components.   

eGraf® materials can be die-cut, laminated with dielectric films, kiss-cut to an adhesive backing with pull-tabs for easy peel-and-stick application, envelope edge-sealed, combined with other flexible materials into a multi-layered material stack, and more! The result is an assembly-friendly heat-spreading solution that can help you cut down on production time and help you launch faster. Talk to a skilled converter before your design is finalized to see how your part can be optimized for better handling, easier assembly, and improved material yield.  

JBC: A Partner for Launch-Ready TIM Solutions 

With an agile engineering team and years of converting expertise, JBC Technologies understands how to support the fail-fast/rapid iteration world of next-generation satellite constellation manufacturing. 

Founded on the pillars of process engineering expertise, manufacturing excellence, and supply chain optimization, JBC is a partner for the entire product lifecycle: from rapid prototyping and design validation to high-volume constellation production and launch. 

Talk to a die-cutting expert about your new-space project today! 

 

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