Aerospace has always pushed the limits of human innovation. After heavier-than-air flight was achieved, humanity has looked ever higher – even to limits of the atmosphere – to space! But as we flew ever higher the material requirement grew, as did the risks.
In flight, you can’t just pull over like in a car. In a airplane, you can land, but in space there is zero margin for error. Once in orbit, there are no options for servicing, part replacement or upgrades. Maintenance is more costly that redeployment. What you have at launch is all you have.
That’s why, here at Element Manufacturing, we’re extremely proud that some of our work has met these harsh conditions and is currently in orbit.
Material Designing for the Harsh Space “Weather”
In low earth orbit, materials must withstand thermal cycling from extreme heat to freezing cold. One orbit can be as little as 90 minutes – that means the full day and night cycle can happen 16 times per Earth day.
Outgassing, material degradation, and microfractures can compromise mission requirements and force a premature end to the mission. This is where advanced manufacturing like Element Manufacturing’s CNC machining and 3D Printing play a critical role, ensuring tight tolerances and material consistency.
Precision Electronics and PCB Assembly
Modern spacecraft rely heavily on compact, high-performance electronics. PCB assembly for aerospace applications requires exceptional quality control. Even minor defects can lead to mission failure. Components must endure the rollercoaster ride of launch, surviving the extreme vibration and forces, and remain stable over long-duration missions in orbit.
Rapid Prototyping with 3D Printing
3D printing has transformed aerospace engineering. Rapid prototyping and complex geometries that traditional manufacturing (even the most advanced CNC) can’t achieve. Lightweight structures, optimized for strength and efficiency, are essential for reducing launch costs while maintaining durability.
Our Contribution to Space Innovation
Our team of engineers, working as manufacturing partners specialising in CNC machining, LSR injection moulding, PCB assembly, and 3D printing, we understand these challenges firsthand. We are proud to have recently produced precision components that will be sent into space, supporting next-generation aerospace missions.
The Future of Space Manufacturing
With the cost-savings delivered by SpaceX, the demand for satellite technology grows, and the prohibitive cost of spaceflight lowers into the realm of everyday companies, advanced manufacturing will remain at the forefront. Companies like Element Manufacturing that can deliver precision and reliability will play a key role in shaping the future of aerospace engineering.