Those outside the aerospace world may find it surprising that engineers spend so much time discussing weight. However, when working on flying machines, weight is an antagonistic force.
If too much weight is added, a system becomes increasingly inefficient, more costly, and harder to cool. Ironically, however, more electronics are being packed into aircraft and spacecraft than ever, meaning that newer systems generate more heat than their older counterparts.
This difficulty has prompted those in the industry to seek lighter thermal materials. Rather than relying primarily on thick plates or machined metal blocks, engineers now have a larger range of tools.
Thin graphite sheets, phase-change materials, low outgassing gap fillers, and electrically insulating thermal pads are all proving their worth in real flight hardware and have now become practical in usage.
Why Weight Still Wins in Aerospace
Aerospace differs from many other industries, since adhering to weight limits is absolutely crucial. Even a small difference can change the price of a launch or the range of a UAV.
In the past, thermal management has been handled with heavier metal components that are predictable and reliable. As electronics keep shrinking and gaining power density, however, this legacy approach often no longer makes sense.
Lightweight thermal materials enable designers to transfer heat without adding unnecessary weight. This is particularly useful as the industry continues to move toward smaller and more densely packed electronic assemblies.
Graphite and Graphene Heat Spreaders
Flexible graphite thermal interface materials, such as UniGraph from Universal Science and PGS Graphite from Panasonic, have become influential additions to thermal design.
These materials are lightweight, thin, and have proven effective at spreading heat laterally across their surfaces. This lateral spreading is incredibly useful for use in compact communication hardware, avionics, and satellite instruments where airflow is limited or even non-existent.
Many engineers like these materials because they behave as expected. They spread heat predictably whilst retaining a compact size, and they weigh only a fraction of an aluminium plate with the same footprint.
Graphene-enhanced materials, such as TG-P100 from T-Global Technology, have also proven to be promising. Their performance varies depending on the composite structure, meaning they require more testing, but they have shown potential.
Low Outgassing Gap Filler Pads
Those who have experience in building space-bound equipment are likely to have encountered outgassing. Anything that releases vapors can create contamination issues, especially if it is near sensors or optics.
Low outgassing gap fillers, like Sarcon from Fujipoly or UniGap from Universal Science, help to solve this problem. They fill uneven spaces between components without requiring a lot of pressure, and stay stable through temperature swings and vacuum conditions, allowing designers to work with tighter packaging and lighter housings, ultimately aiding the entire system.
Phase-Change Materials in Thermal Interfaces
Phase-change materials, such as UniPhase from Universal Science or TPCM from Laird, start out firm enough for easy handling but soften once the device heats up. This softening helps them settle into the microscopic gaps that would otherwise limit heat transfer.
These materials are particularly useful in configurations that experience short bursts of high power, similar to the load changes common in avionics and satellite electronics. Whilst they do not offer the highest standalone conductivity, they help to reduce weight by providing superior energy density, assisting the user to create lighter, more compact systems when compared to traditional methods.
Electrically Insulating, Thermally Conductive Pads
Many aerospace components require electrical insulation while dissipating heat. Traditionally, this meant that using metal-backed or ceramic insulators was necessary, in turn adding weight. More modern insulating thermal pads, such as Keratherm from Kerafol and T-Pad from Universal Science, retain electrical separation whilst providing a cleaner heat path, achieving this at a much lower weight.
They are frequently found in motor controllers, power supplies, high-voltage regulators, and other compact electronics where reliable safety is crucial.
What These Lightweight Materials Actually Change
When such materials are combined, there is a clear impact on the system design, allowing engineers to reduce mass, improve temperature stability, and place electronics more efficiently. There is less need to rely on thick metal blocks to soak heat, granting designers the freedom to reconsider how components fit together.
Systems tend to last longer, run at a cooler temperature, and handle higher power densities without creeping into dangerous temperature ranges.
How Materials Direct Helps Aerospace Teams Source These Materials
Materials Direct carries many of these thermal materials that are already being used in aerospace applications. Items such as low-outgassing gap fillers, graphite spreaders, phase-change materials, and insulating pads are available in both standard sheets and custom-cut shapes.
The custom-cutting option is particularly useful, as aerospace components rarely follow basic geometry. Having materials delivered in a specific shape simplifies assembly, saves weight, and avoids the need for machining or trimming parts. The website also includes technical data for each material, making it easier to match them with strict aerospace requirements.
Looking Forward
Thermal management is not getting easier. Electronics keep getting smaller, while the heat they generate keeps increasing. Lightweight thermal materials will remain essential for keeping temperatures controlled without adding the mass that aircraft and spacecraft cannot afford.
Graphite, PCMs, gap fillers, and insulating pads are already influencing the design of new systems. As these materials evolve, they will continue to enable lighter, cooler, and more efficient aerospace technologies.
This information has been sourced, reviewed, and adapted from materials provided by Materials Direct.
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