From the earliest days of space exploration, materials considerations have played a fundamental role in the development of space technology. Decisions regarding materials selection and design set strict limits on mass, durability, thermal stability, and survivability in a hostile environment different to any experienced on Earth. Over the past seven decades, spacecraft materials have progressed from relatively simple metallic structures to carefully engineered, multi-material systems optimised for extreme environments. More recently, advances in composites, additive manufacturing, and functional materials have reduced mass and cost while enabling new spacecraft architectures. Below, we consider three case studies that illustrate how materials innovation is shaping modern space systems.
Case Study 1: TISICS – Lightweight Components Using Metal-Matrix Composites
TISICS, a UK-based company, has developed fibre-reinforced metal-matrix composites by embedding siliconcarbide mono-filaments within metal matrices to form pressure vessels and structural components. These components can achieve up to 70% mass reduction, up to 80% lead time reduction, and 80% less waste during manufacture. TISICS have received funding from the UK Space Agency to develop demisable launcher components that will burn up on re-entry, reducing the risk of damage to spacecraft by space debris.
Case Study 2: LignoSat – Wood as a Space Qualified Material
In 2024, LignoSat, developed by Kyoto University and JAXA, became the first wooden satellite when it was launched from the ISS. Built with panels of magnolia wood, the satellite was deployed to investigate the survival and breakdown of alternative satellite materials in the harsh conditions of space, with a view to reducing reliance on conventional metallic alloys[IS1] [MB2] . Plans for a second satellite are already underway, with hopes that this could provide a sustainable and renewable source of materials for future space vehicles.
Case Study 3: Oxford Space Systems – Deployable Carbon Fibre Antennas
Oxford Space Systems (OSS) has enabled large aperture antennas on small satellites through deployable structures based on carbon fibre composite ribs. Its wrapped-rib design allows antennas to be tightly stowed for launch and precisely deployed in orbit. Once deployed, the ribs support a metal mesh reflector, providing up to a 16-fold increase in antenna area. OSS antennas have flown in orbit and have been selected by Airbus Defence and Space for the UK’s Project Oberon radar satellites.
Conclusion
These case studies illustrate the breadth of materials-led innovation occurring at the forefront of space technology. Advances in material design and manufacturing are enabling development and optimization of the next generation of satellites and spacecraft, with sustainability as a key focus. Lighter, stronger, and smarter materials allow spacecraft to be launched more efficiently, operate more reliably in harsh environments, and reduce their long-term impact on the space environment.
As the boundaries of space technology continue to expand, continued progress in the materials that underpin these systems will play a central role in enabling the next giant leaps in space exploration.
Max Bertrand
Max has experience in range of patent work, including drafting, prosecution and infringement matters, in the engineering, mechanical and chemical engineering fields. He also advises on Freedom-to-Operate, global portfolio management and design rights and has worked with clients ranging from SMEs to multinational corporations. Areas of Expertise Medical devices and med-tech, including surgical devices Manufacturing and consumer products Semiconductor fabrication Oil and gas exploration and extraction Aerospace engineering Composite materials Background.
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