Technologies for New Space applications

We develop innovative thermal management solutions for space applications. We specialize in cooling and temperature control solutions for small and medium thermal loads using Peltier cooling or special heat pipes. Fraunhofer IPM´s portfolio also includes thermal simulations, structural and thermal characterization of materials, components and systems, as well as thermography and thermal failure analysis.

Peltier cooling technology

Peltier elements are characterized by their short response times, high temperature stability and wide temperature range. They are maintenance-free and operate without noise or vibration. Fraunhofer IPM has been conducting research in the field of thermoelectric generators and Peltier cooling modules for over 30 years. We cover the entire production chain, from the design and preparation of basic components to complete, quality-assured module production systems. We develop, build and characterize individual system solutions on behalf of our customers. In addition to standard TEC (thermoelectric coolers) planar designs, we specialize in advanced TEC designs such as the novel tubular TEC design “RO-PELT” (patent pending).

Fabrication and characterization

Fraunhofer IPM is capable of fabricating batches of Peltier cooling modules on its own in-house module production line, thus ensuring independence from non-European suppliers and avoiding geopolitical risks. A range of different measuring setups are available at the institute that allow us to precisely characterize the thermoelectric properties and long-term stability of Peltier modules. We carry out destructive and non-destructive analyses using 3D computed tomography. We also conduct failure analyses and composition analyses using a scanning electron microscope, which also includes the preparation of micrographs. more about Peltier cooling technology at Fraunhofer IPM

Heat pipe technology

Heat transfer in a heat pipe takes place via latent heat, i.e., the evaporation and recondensation of a fluid, making it highly effective. Fraunhofer IPM develops and implements heat pipes for industrial and research aerospace applications. The focus is on special heat pipe designs, such as pulsating heat pipes and switchable heat pipes (i.e., heat switches based on heat pipes), that are not yet commercially available. Our research activities in the context of heat pipes cover a broad range of different approaches and methods, from welding and soldering of heat pipes to creating wick structures, as well as prototypes (also using additive manufacturing) and applying various working fluids. Special measurement setups and IR thermography are used to characterize the heat transfer capability of tubular and flat heat pipes. To investigate the internal structure of heat pipes, a state-of-the-art 3D computer tomograph is used. (More about heatpipe technology for space applications at Fraunhofer)

Advantages

Commercial suppliers of thermal management solutions often focus on large-scale applications, using standardized, mass-produced parts. By contrast, Fraunhofer IPM offers specialized products and services that are typically not commercially available.

We develop cutting-edge solutions for magnetic inspection and magnetic shielding for space applications.

Current research at Fraunhofer IPM focuses primarily on quantum-based optically pumped magnetometers (OPMs) that allow magnetic field measurements with unparalleled sensitivities.

Measuring magnetic cleanliness in a magnetically shielded room (MSR)

Magnetic cleanliness is becoming an increasingly important issue as more and more satellite missions rely on commercial off-the-shelf components (COTS), which can have slight permanent magnetizations that interfere with the satellites attitude control.

In our MSR, we measure the magnetization of nanosatellites in a matter of minutes. We use sensitive magnetic field sensors to detect minimal residual magnetization and guarantee a magnetic budget of 0.03 Am², which can impair magnetic cleanliness. Our measuring technique helps nanosatellite manufacturers monitor the production process and identify critical components, thus reducing risks and extending the lifespan of satellite missions.

Our services for magnetic measurements

• Consulting and studies
• Dedicated magnetic test infrastructure
• Simulations of magnetic systems and magnetic field distributions
• Magnetic materials testing
• Innovative materials and designs for magnetic shielding 
• Magnetic cleanliness measurements

Space missions allow no room for failure, regardless of how small the component. Traditionally, space components undergo rigorous qualification and screening processes to ensure they meet space mission requirements. The increasing use of commercial off-the-shelf (COTS) parts in commercial space applications creates the need for advanced quality inspection methods and traceability. The responsibility for quality assurance of COTS parts lies with the manufacturer, rather than the space organization purchasing the parts.

Research for Production Control at Fraunhofer IPM is focused on customized optical systems and imaging methods for inspecting or analyzing surfaces and 3D structures in production and controlling manufacturing processes. These systems can detect dimensional accuracy, small surface defects or areas of contamination on components even at high production speeds, enabling 100 percent quality assurance during production. The robust inspection systems are designed for 24/7 use. Our systems are employed in various industrial sectors, from forming technology and automotive manufacturing to medical product quality control. A wide range of methods are used, including digital holography, infrared reflection spectroscopy and fluorescence methods that are combined with fast, low-level image and data processing. Our Track & Trace Fingerprint component tracing method enables component authentication without the need for markers, using their distinct microscopic surface.

Our services for quality assurance of precision parts

• Surface analysis and materials testing
• Surface inspection
• Geometry measurement
• Marker-free component identification
• Deformation measurement

Material testing is crucial in the aerospace industry, particularly in the design and operation of turbines. These tests are essential for verifying material properties and ensuring they can withstand extreme conditions, such as high temperatures, pressure and mechanical stress. This is where innovative strain measurement technologies, such as those used in our RODiS (Real-Time Optical Displacement Sensor) system, come into play. The RODiS system enables the precise, non-contact measurement of strain and displacement in real time using digital image correlation (DIC) technology. By evaluating high-resolution images at frame rates of up to 2000 Hz, even the slightest relative movements and deformations can be accurately recorded, right up to a full-field evaluation of cracks. This combination enables precise monitoring of dynamic changes in materials under extreme conditions.

Lasers are indispensable tools in various fields, such as measurement or quantum technology. They can, for example, be used to gather wavelength-dependent information as in spectroscopy, or to target specific atom transitions crucial for quantum computing. However, wavelengths are often needed that are not available off the shelf.

We specialize in utilizing nonlinear optical frequency conversion to enable tailor-made wavelength solutions from the UV to the MIR, bridging the gap between readily available laser wavelengths. We can provide everything from widely tunable ranges and single wavelengths to feasibility studies and production ready prototypes with several watts of output power. Our most versatile light source to date is currently being developed in the Octopus project and will deliver cw laser light in the continuously tunable wavelength range from 300 nm to 3000 nm.

We also use our own light sources and expertise to develop measurement setups for applications such as quantum sensing and the quality control of high-performance optical materials.  

We develop cutting-edge technologies for analyzing, validating or complementing satellite data. For this we offer:

• Custom-built 2D and 3D measurement systems for both urban and rural environments
• Full software development across the data processing chain
• Deep learning-based automated data analysis using artificial neural networks (ANN)
• Multispectral and semantic segmentation capabilities
• Visualization tools for intuitive decision-making
• Robust, high-precision tools for satellite data validation and calibration (e.g. thermal data)