Connectors & cables W
hile there is no universally accepted categorisation for small- size satellites, the most prevalent classification is based on mass
and size. Minisats typically weigh between 100 and 500 kg and are used in telecommunications and meteorology at low Earth orbit. Microsats weigh less than 100 kg and are ideal for scientific research, while nanosats, weighing only 10 kg are used in educational experiments and for remote sensing networks like LANet.
The smallest category, femto satellites use innovative nanotechnology to create an exceptionally miniature satellite that weighs under 100 grams. Femtosats’ primary functions include image capture, testing of innovative technologies, biological experiments and asteroid landings. The number of satellites launches continues to grow, reaching 2,304 global launches in 2023 and projected to reach 11,631 by 2030. Nevertheless, regardless of satellites size or mission, their performance and longevity is highly dependent on the choice of interconnected solutions.
MISSION-CRITICAL CONNECTORS Space is a harsh environment for electronic components of all types. Outgassing, UV radiation, vacuum and oxygen conditions and the unique harsh environment factors of low Earth orbit require careful consideration in connectors selection. Connectors need to be light and compact and optimised for weight and size.
One major challenge in space missions is outgassing, a phenomenon where certain materials release gases in the vacuum of space. This can cause serious damage to components, clouding lenses and contaminating sensors. Materials like certain plastics, adhesives and, even, coatings are particularly prone to outgassing, which is why space-grade connectors often use specially treated metals like stainless steel, aluminium alloys, and gold-plated contacts.
Polytetrafluoroethylene (PTFE) and ceramic- based insulators are also popular choices because of their low-outgassing properties. These materials help protect the satellite’s critical systems and ensure long-term functionality.
Temperature fluctuations are another concern. In space, satellites can swing from blistering heat to freezing cold in minutes. Space-grade connectors are built with materials like beryllium copper and nickel alloys, which maintain their electrical performance and structural integrity despite this extreme thermal cycling.
Then there’s vibration. The launch phase subjects satellites to intense mechanical stress, with powerful forces threatening to shake loose or damage poorly secured components. During liftoff, vibrations can exceed 7.5 g RMS (root mean square of acceleration), which is enough to dislodge poorly constructed hardware.
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SMALL SATELLITES, BIG IMPACT
Small satellites have transformed space-based observation, making space missions more agile, affordable, and precise. Ranging from the size of a refrigerator to a shoebox, these spacecraft provide real-time data on rising sea levels, extreme weather, and environmental shifts, helping governments and organisations make faster, smarter decisions. But behind the seamless operation of these advanced systems lies a crucial component: space-grade connectors. Here, Joseph Horsky, North America product team manager at space-grade connector specialist PEI-Genesis, explores the role of connectors in ensuring steady connectivity for smallsats.
High-quality connectors are engineered with reinforced locking mechanisms, flexible contact designs, and ruggedised casings made from titanium or stainless steel. These features help the connectors stay firmly in place and continue transmitting data without interruption.
SHIELDING AGAINST INTERFERENCE Once in orbit, satellites face yet another challenge: electromagnetic interference (EMI) and radio- frequency interference (RFI). Space is filled with radiation and environmental noise that can disrupt electronic systems, potentially corrupting data or impairing communications.
Space-grade connectors come equipped with advanced shielding to block out this interference, ensuring that the satellite’s signals remain clear and accurate. For climate and disaster monitoring, where every piece of data can inform critical decisions, this level of reliability is absolutely essential.
As the demand for space-grade components continues to rise, companies like PEI-Genesis are contributing to the advancement of interconnect technology. Space-grade connectors, such as MIL-DTL-38999, D-Subminiature, Micro- Miniature, and push-pull connectors are all engineered to withstand the extreme conditions of space. These components are essential in supporting systems such as propulsion control for launchers, communication and imaging for satellites, navigation for rovers, and other critical subsystems.
In addition to providing high-reliability connectors, PEI-Genesis also offers in-house outgassing services, which can help streamline processes and reduce time and cost for space projects.
PAVING THE WAY FORWARD As smallsat technology continues to evolve, the demand for even more sophisticated and resilient connectors grows. Innovations in
September 2025 Instrumentation Monthly
miniaturisation, material science, and shielding are driving the development of next-generation connectors that are smaller, lighter, and more powerful than ever before.
Additionally, the integration of edge computing and AI into smallsat designs is accelerating their capabilities, allowing for more autonomous operations and real-time data analysis in orbit. With satellite launches continuing to rise and missions become more complex, the evolution of connector technology will play a central role in driving the future of space-based observation and exploration.
PEI-Genesis
www.peigenesis.com
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