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High-Performance Plastics for Space Applications

Performance That Overcomes Extreme Conditions

In space applications, compromise is not an option. Components must operate reliably under vacuum conditions, high radiation exposure and extreme temperature fluctuations. This is often required over many years, without any possibility of maintenance during operation.

Satellites, launch systems and ground stations therefore require materials that withstand these extreme conditions and ensure reliable operation. Thanks to our comprehensive materials expertise and many years of experience in plastics manufacturing, we can respond precisely to your application requirements – from individual functional parts to complex systems.

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Materials for Space Applications: Precisely Matched to Requirements

In space applications, the choice of materials and their processing are largely determined by the specific mission and system requirements. Ensinger offers a comprehensive range of high-performance plastics for use in vacuum environments, under high radiation exposure, at cryogenic temperatures and under high thermal loads.

Depending on the application, the materials are available as semi-finished products, precision machined parts, moulded parts, profiles, filaments or composite solutions.

Polyimide (PI)

For particularly demanding requirements in terms of cleanliness, outgassing and temperature resistance. PI offers high strength from -270 °C to +350 °C, as well as exceptionally high dimensional stability.

Polyetheretherketone (PEEK)

Resistant to high-energy radiation and chemical influences, inherently flame-retardant and suitable for vacuum applications. Also suitable for direct laser structuring.

Polyetherimide (PEI)

Highly resistant to thermal and mechanical loads, radiation-resistant and suitable for vacuum technology.

Polyetherketonketon (PEKK)

High thermal and mechanical performance combined with inherent flame retardancy – available as a filament for additive manufacturing. 
 

Liquid Crystal Polymer (LCP)

Suitable for HF/RF antennas and three-dimensional interconnection technology. Its excellent dielectric properties, low signal attenuation and high dimensional stability make LCP suitable for HF/RF antennas and 3D interconnection technology. Thermal expansion remains low even during severe temperature fluctuations in space.

Polytetrafluoroethylene (PTFE)

Excellent sliding and friction properties, including in cryogenic applications.

Solutions for Space applications

Satellite systems

For satellite platforms, Ensinger supplies components for solar panel deployment systems, thermal spacers, cable insulation and parts for platform and box systems. Materials such as PI, PEEK and PEI combine low weight with the required thermal, mechanical and electrical performance.

Antennas & High-Frequency Application

LCP solutions are available for HF/RF antennas and three-dimensional interconnection technology, among other applications. Applications also include metasurface antennas for LEO systems and antenna mounts exposed to high thermal loads.

Propulsion and Deployment Systems

Bearing cages, sliding guides and components for ion propulsion systems require high dimensional stability and robust tribological properties – even under vacuum and at extreme temperatures. TECASINT materials based on polyimide, in particular, offer proven solutions.

Benefits for space applications

  • A significant reduction in component mass can reduce fuel requirements and launch costs
  • High mechanical and tribological performance
  • High strength, stiffness and wear resistance – even under cryogenic conditions and without lubrication
  • Resistance under extreme environmental conditions
  • High resistance to vacuum, cosmic radiation and severe temperature fluctuations
  • Application-specific material modification available

Flight Heritage: Proven in Space

Selected TECASINT materials have already been used in space missions.

Material

Key Properties

Example Application
TECASINT 1011 Good temperature resistance up to 280 °C,
high stiffness		 Thermal washers and spacers,
BepiColombo mission
TECASINT 2011 Good toughness and stiffness, improved thermal ageing,
lower outgassing than TECASINT 1011		 Wire coils, EstCube-1; thermal spacers for sensors 
TECASINT 2391 Contains molybdenum disulphide for very good tribological properties in space Taper inserts, hubs for wire coils, gears and bearings 
TECASINT 4011 High-temperature grade with good toughness and high dimensional stability Components for ion propulsion systems,
Eutelsat 172 B / SES-12 
TECASINT 4111 For the highest thermal requirements,
HDT of 470 °C, low water absorption, high stiffness		 Satellite components exposed to extreme heat, antenna mounts, NORSAT 2 

One-Stop Shop: Your integrated partner for space solutions

Ensinger supports space projects throughout the entire value chain: from developing application-specific compounds and composites, through semi-finished products such as sheets, tubes and rods, to functional finished parts and assemblies.

All key processes are available in-house. This ensures continuous technical responsibility, short coordination paths and a reliable basis for qualifying materials and components.

Experience, Qualification and Collaborative Support

Long-standing collaboration with leading companies in the space sector and a deep understanding of the supply chain form the basis of our advice. Ensinger operates four AS/EN 9100-certified machining sites in France, the United Kingdom, China and the USA.
Our experts support you from the concept phase through the qualification of materials and components to the final approval of the end product.

Case Study within Space

Thermal spacer

made of TECASINT

With Bepi Colombo to Mercury
Ensingers TECASINT material is part of Europe's first mission to Mercury with BepiColombo. The spacecraft for the mission are dependent on the function of the thermal control system (TCS), which keeps all the spacecraft's component systems within an acceptable temperature range during every phase of the mission. One part of the TCS is a thermal spacer, which functions as a barrier to high temperatures and radiation. This thermal spacer is a ring shaped plate made of TECASINT.

FAQs

  • For an initial technical assessment, information on the operating environment, temperature range, vacuum and outgassing requirements, radiation exposure, mechanical loads, quantities, as well as drawings or 3D data is helpful. On this basis, Ensinger can assess technical feasibility and identify an appropriate solution approach at an early stage.
  • Yes. From the concept phase onwards, Ensinger supports customers with material selection, component design and the qualification of materials and components – through to final approval of the end product.
  • Yes. Additives and fillers make it possible to tailor materials specifically to the requirements of an application – for example with regard to mechanical, thermal or tribological properties. Our application engineers will support you.
  • Ensinger supplies both materials and functional finished parts and assemblies. The portfolio includes compounds, composites, semi-finished products, filaments, injection-moulded parts, sintered plastics, profiles and precision-machined components.
  • The required evidence depends on the application as well as customer and programme requirements. Requirements concerning material data, outgassing, traceability, documentation and component testing should be agreed at an early stage.
  • Ensinger combines a global presence with qualified manufacturing capacities for space applications. Four AS/EN 9100-certified machining sites in France, the United Kingdom, China and the USA enable international support and the production of precision parts. Complemented by a worldwide sales and production network, Ensinger can support projects across locations and adapt supply routes to regional requirements.
    For function-critical components, we agree requirements, scope of supply, production site and project planning with our customers at an early stage. This reduces interfaces and helps establish a reliable supply solution for the respective application.

Discuss your space application with us

Are you looking for a lightweight, vacuum-suitable and durable material or a precision-manufactured plastic component for your space project? Download our brochure and contact our experts to support you with material selection, design and qualification.
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High-Performance Polymers for extreme Space Conditions