Established Satellite PCB Manufacturer in China

The Satellite PCB Manufacturer You Deserve

The type of Multilayer PCB you require depends on the applications you will use it for. Today’s high-tech needs are answered by satellites. These devices need sound Satellite PCBs. For this type of PCB, you can rely on PCBMay.

• Thermal specifications suitable for aeronautical applications
• Signal transmission with a transponder is excellent.
• Shock and radiation are not a problem for these PCBs
• Made to be light enough to take to outer space
• PCBs follow specs to the letter — there is no room for error.

Buying a PCB from us is only one part of our business relationship. Because we want to improve your experience, you can expect above-board customer service.

We can design your board with modern software as a turn-key vendor of Satellite PCBs. For example, we can help with your Gerber files using Kicad PCB or Eagle PCB.

If engineering precision is important to you, we can provide you with both a CAD and a CAM report. When it comes to the fine details of a Satellite PCB, there are significant variations, and we want to make sure you’re on the right track.

We can also provide Box Assembly and Backdrill PCB services, according to your needs. In addition, we can also support you with OEM PCB services.

We will adjust to your time zone regardless of where you are in the world. Just give us a call!

Finally, we provide a variety of payment options. We are certain to win you over because of our affordable pricing.

Now, inquire about your Satellite PCB! There is no time to waste.

Satellite PCB: The Complete FAQ Guide

Satellite PCBs are part and parcel of satellite-related equipment. We think you know about satellites. Also, it becomes more complex in terms when it comes to satellite PCBs.

Therefore, there are many things to know about satellite printed circuit boards when developing satellite equipment. There are a lot of questions that might be generated related to PCBs used in satellite-related electronics.

You may not know how satellites work, how PCBs make a function, PCB design process, or many things.

Regarding satellite PCBs, we will discuss and answer some highly related questions here. We hope these would help understand things about satellite printed circuit boards.

What Is Satellite PCB?

In nature, a satellite is a moon, which surrounds our planet Earth or other orbiting planets, such as the earth. Satellites, on the other hand, also are devices launched by humankind that orbit the earth or other planets.

NASA launches hundreds of satellites into orbit. They take photos, transmit data, and monitor weather situations including hurricanes and storms.

Most satellites are used for communication rather than navigation.

Printed circuit boards, on the other hand, are the functional supporting boards used in electronics. PCBs enable the installation of several components, each with its own function in an electrical system.

Satellites are electrical devices that need printed circuit boards. As a result, the satellite PCBs provide power to the satellite equipment to work.

The aerospace and satellite sectors have a great need for printed circuit boards (PCBs) with excellent reliability and performance at a high level. The aerospace sector creates satellite PCBs for use in the aerospace industry.

High Frequency Satellite PCB

Satellite PCBs should be expected to provide high-level circuit design and connection. As a result, while designing a satellite PCB, you must guarantee that the PCB has excellent thermal, mechanical, and electrical performance.

What Are The Materials Of Satellite PCB?

The satellite PCBs operate in a vacuum condition. They need to withstand a high temperature when exposed to sunlight. Actually, the temperature is extreme.

On the other hand, aside from the sunlight, the temperature is hugely low and cold in space. Because then, the satellites work in no atmospheric regulation.

So, basically, the satellite PCB materials have to withstand different types of extreme temperatures. By considering the facts, the material of a satellite PCB must have great thermal properties.

On the other hand, the materials only should not be withstandable with high extreme temperatures, but also should have a very low changing of dielectric constant.

You will get the reflection of the stability of the material from its coefficient of dielectric constant. It is a must to use satellite circuit boards materials with a low changing of coefficient of dielectric constant.

Basically, the satellite works in between -55° to +125°C temperature, along with the Dk value of 3.27 to 12.85 on the z-axis. So, the material that copes up with the situation should be used in satellite materials.

PTFE-based materials are used in satellite PCBs. Kapton is one of the most used materials. It is one kind of flex polyimide. It is lightweight, as well as vibration-resistant. It withstands the environment of the space while used in the flex PCBs.

PTFE Based Kapton Material

Trimethylenemethane hydrocarbons are among the popular ones. It is highly reliable because it is made of the composition of hydrocarbons, ceramics, and thermosetting polymers. Its Dk value ranges from 3.27 to 12.85 which is the preferred range for satellite PCB materials.

How Does A Satellite PCB Operate?

Essentially, the satellite sends signals to the earth station to establish contact. Transceivers are used to establish contact between the terrestrial channel and the satellite. The satellites transmit and receive data via the transceiver.

The earth station primarily transmits high-frequency communications to the satellites. The signals are received by satellite, which then re-transmits them with the relevant information.

The signal from the satellite PCB is then received by a receiving station on the earth. The area in between the receiving signal on the earth from the satellite is called the satellite’s footprint.

The Working Process Of Satellite

The satellite, receiver, and transmitter are the main elements of a satellite system.

The communication between the earth and the satellite is known as uplink when the earth sends the signal to the satellite through the transmitters.

On the other hand, the name is changed for the communication as downlink, when the earth receives the signal through the receivers.

The following video shows how satellites work.

What Are Major Satellite PCB Types?

There are three main types of satellite PCB services used in satellite. They are,

Broadcast Satellite Service (BSS)

We watch TV and listen to the radio. The dish services provide TV signals through the satellite.

Fixed Satellite Services (FSS)

FSS has used a fixed receiving station. The fixed receiving station provides signals to the end-users. Basically, land stations are utilized to receive and transmit the signals.

Fixed Satellite Services (FSS) Process

Mobile Satellite Service (MSS)

The MSS systems work with mobile communications actually. However, this type of satellite service is also used in communicating among the water vessels like ships and others.

Where Do You Use A Satellite PCB?

Man Made satellites are used for the advancement of technology. Satellite PCBs are the role players in the functioning of the entire satellite system. With the following uses of satellite PCBs, we are getting conveniences from modern technology.

Communication

Satellite PCBs are used in aerospace communication systems. Like phone communication in the flight system. Also, in the area where cable lines are not available or damaged, wireless satellite communication through radio frequency takes place.

Communication Is One Of The Main Uses Of Satellite

Television

Satellites provide TV broadcasts directly. The satellite also broadcasts on cable TVs. Basically, the satellite sends a signal to a central station, which then distributes it to TVs through cable networks.

Navigation

Satellite empowers the Global Positioning System (GPS). You can determine your location by GPS tracking through a handheld device by satellite.

Satellite-based navigation is able to be used in any situation and environment like sea, land, and air. So, civilian and military, or aerospace industries use satellites for GPS.

Weather Monitoring And Safety

Meteorologists use satellite information to analyze global weather conditions. As a consequence, they can utilize satellites to predict storms, hurricanes, volcanos, gas and oil fields, and more.

Satellite data is used to research climate change. Satellites contribute to large-scale weather and climate monitoring. You can forecast long-term rainfall, sea-level fluctuations, and the influence of greenhouse gasses.

Earth-observing satellites detect environmental disasters, forest fires, etc.

Development Of Space Science

The satellite is an important accomplishment in space research. Satellites contributed to space science, and satellites are actively advancing space research.

Satellite telescopes are used to study pulsars and black holes. You may have heard of the Hubble Space Telescope. It is humanity’s most important astronomy tool.

What Are The Benefits Of Satellite PCB?

Satellite PCB communications have the following advantages in terms of technology.

Satellite Facilitates Wireless Communication

• You can vastly cover a large area to connect through satellite. Almost, the entire world.
• Satellite offers high bandwidth facilities.
• Satellite provides wireless communications. Mobile communication, radio communications are examples of wireless communications.
• Satellite is used for different purposes such as long-distance phone calls, private business networks, weather forecasting, climate change monitoring, remote and cable network establishing, broadcasting, and so on.
• You will get optimized and uniform services through satellite.
• In the created critical situation, the satellite station could be removed and reinstalled in other places.

Which Surface Finish Is Suitable For Satellite PCB?

The surface finish is the metal coating of the exposed copper of satellite PCBs. Surface finishes provide protection to the PCB copper from corrosion and oxidation.

Therefore, it is one of the most essential parts of PCB manufacturing. There are different types of surface finishes used based on the needs of PCBs. Following are the some most popular surface finishes to describe.

Hot Air Solder Leveling (HASL)

Hot Air Solder Leveling, or HASL is the most common type of surface finish. It is also the cheapest one. So, you have to consider the environment concern while using it. It is not lead-free, as well as non RoHS compliant.

With this surface finish, manufacturers use hot air knives to remove if any residual exists in the surface finish PCB.

ENIG And ENEPIG

ENIG stands for Electroless Nickel Immersion Gold. The gold combined with nickel is used for protecting copper, where nickel protects copper, and the gold protects the nickel.

ENIG Surface Finish On The PCB Surface

On the other hand, another developed version of ENIG is the ENEPIG. Electroless Nickel Electroless Palladium Immersion Gold is different from an extra palladium layer. However, these two are expensive and provide the highest level of copper protection.

Immersion Silver (ImAg)

Immersion silver is the coating of silver on copper. Silver plating is used over the conductive copper traces to protect them from corrosion. They are environment friendly, and lead-free RoHS compliant. ImAg does not affect the hole size of the PCBs.

Immersion Tin (ImSn)

Immersion Tin uses a tin coating to preserve the copper, similar to Immersion Silver. It guarantees that the surface is flat and free of dimples. It also works with the AOI testing approach.

Organic Solderability Preservatives (OSP)

OSP is a water-based, transparent surface treatment. It employs a water-based organic molecule that forms a bind with copper. It has a quick and simple implementation method. It’s also reasonably priced and reworkable.

What Is The Power Level Of GPS Satellite PCB?

The continuous wave jammer to GPS satellite signal ratio may be as high as +30dB at its most extreme setting. Using a GPS signal with its power level set to -125 dBm, the maximum jamming signal is -95 dBm.

You will see that the out-of-band IIP3 requirement is +57 dBm at the very least. GPS receivers with the aforementioned power levels.

It is possible to notice a 3 dBm when the out-of-band IIP3 is +60 dBm at certain times. The cumulative out of band IIP3 power, on the other hand, exceeds 60 dBm.

While on the other side, for the GPS to work properly, the minimum band requirement of +57 dBm may easily be obtained. As an alternative, by using fewer external components, the amount of electric current used will be reduced as well.

Why Are Flexible PCBs Effective For Satellite Applications?

As satellite PCBs are sensitive, the type of PCB selection based on construction is an important issue. By the way, using flexible PCBs over other types of PCBs in satellites has several advantages.

Flex PCBs Are Reliable For Satellite

Because of the advantages, almost all types of satellite PCBs use flexible PCBs made of high-grade PCB materials.

• The reliability of the satellite PCBs is highly important. The PCBs with dynamic flexibilities are highly durable and withstand adverse situations. Some of the satellites in space have been given services for 30 years and more. Flexible PCBs are more reliable and highly durable.
• Flexible PCBs are highly adaptable with any type of component. On the other hand, you need adaptability when you design a PCB for a satellite.
• Flex PCBs are compact in size. On the other hand, they are lightweight as well. So, you can minimize the size and weight to the minimum level by using flex PCBs in satellite.

What Is The Best Component Mounting Process For Satellite PCB?

The component mounting technology is the way by which the PCB manufacturers mount PCB components on the PCB boards.

Through-Hole Technology(THT) and Surface Mount Technology (SMT) are the two most popular component mounting technologies.

Before SMT, the THT was the only way to mount PCB components. Let’s briefly know about these two first.

Through-Hole Technology (THT)

THT is the process where you need to drill the PCB board and then mount the component on them. After placing the components you need to solder the component with the solder pads.

You Need To Drill The PCb Board For THT

THT is highly preferred for the PCBs that need stronger connections whereas multiple layers are connected.

Surface Mount Technology (SMT)

SMT technology directly places the components on the surface of the PCB and solders them. It does not need to drill or hole the PCB boards. SMD- Surface Mount Devices can be placed on both sides of the PCB boards.

Basically, smaller applications use SMT. It does not need a much stronger connection load.

So, based on the needs of your PCB implementation, you need to choose the component mounting technology for your design.

Let’s see how SMT works with manual and semi automatic processes.

What Is The Design Process Of A Satellite PCB?

PCB design is the first way to enter into the manufacturing of PCBs. So, before starting manufacturing, you must follow some design rules to design a satellite PCB. Because designing the PCB is the most sensitive part of a PCB manufacturing process.

Proper Schematic Is The Beginning Point Of Designing A Satellite PCB

So, you should follow the following steps.

• Create the PCB schematic first before manufacturing the PCB. A schematic is a PCB’s blueprint. You will develop and complete the PCB-making procedure based on the schematic.
• Consider component positioning. Do this depending on the schematic’s circuit design. Organize the components into divisions according to their needs.
• Routing comes next after component placement. Make sure the components operate with the routing before moving on to production.
• Set the board’s shape. Decide on the PCB board type. In the design process, you must additionally specify the PCB layer
• Before finishing the manufacturing process, the PCBs must be tested for faults. During this step, you would remedy any issues detected.

How To Make A Satellite Receiver PCB?

While you are finishing the designing of your satellite PCBs, now the time is to go for the manufacturer. To manufacture the PCBs, there are several manufacturing process steps to go through.

They are as follows.

Design The Board Layout

Use the PCB design tools to design the board layout. You need to design in a compatible format for your manufacturer. The most frequent PCB file is called Gerber PCB files.

Design The PCB Board Layout As The Part Of PCB Manufacturing

Most of the manufacturers will ask for the Gerber file from the designer to go for the manufacturing process.

Conversion Of The File

The PCB manufacturer will now transform the Gerber file into an image format. The manufacturer will first examine the schematic and DFM.

The maker must print the PCB image using a plotter on the PCB board.

You will get a black ink image negative. The inner copper layers of the PCB are represented by black ink.

Printing The Image On PCB Board

This is the actual printing of the PCB image. Organize the layer stack-up of the PCBs based on layer counts. In general, the board is made of flexible yet high-quality materials.

The layers on the board are organized using associated materials.

Layer Alignment

The technician will align the layers after sorting them. They must be suitably positioned. The technician will next use an optical punch machine to connect the holes.

After that, firmly connect the layers. The exterior prepreg and copper layers will be joined using metal clamps on a steel table.

Drilling

After finishing the board’s construction, drill holes for the components. In this stage, vias are used to connect the layers.

After drilling the holes, the PCBs need to be protected by plating, coating, and finishing. First, etch conductive traces to carry electricity across the PCB.

After the steps, do an electrical test to check the PCBs functionality. The PCBs are ready after the test.

The V-scoring PCB step is required to separate the PCBs from the single panel. For easy board removal from the panel, a V-groove cutter makes short v-lines.

What Are The Required Considerations For Developing Satellite Technology?

It is certain that a satellite PCB might be used in any layer of the earth’s atmosphere. So, in this case, you need to consider some things extensively for designing a PCB.

Determine The Outer Environment For Developing Satellite Technology

• Determine and know the internal environment that your satellite PCBs are going to be installed. Design them as per the environment.
• Also, know about the orbital environment in which your satellite is going to be orbiting. Design the outer physical bodies of the satellite as per the environmental compatibility.
• Know about the mission extensively. It will help you to design the satellite based on the complexity of the mission.

As you are designing an uneven environment of space, which is different from the earth, you need to keep in mind the different atmospheres of the earth.

How To Test A Satellite PCB?

Testing is the way to find out any flaws in the PCB while making. There are various testing methods available to test the satellite PCB during the manufacturing phase. The following are the most popular testing methods of PCBs.

In-Circuit Testing (ICT)

It actuates all circuitries of the PCB individually. ICT is designed for 100% coverage of the circuit. However, with the ICT testing, you will always get up to 90% coverage. ICT is also known as the bed of nails test. Also, it is the most expensive testing method as well.

In-Circuit Testing Actuates Every Circuit Of The PCBs

Flying Probe Testing

It is the short version of ICT. It is designed for testing specific areas of the PCBs, like opens, shorts, resistance, capacitance, etc.

Automated Optical Inspection (AOI)

AOI uses single 2D or two 3D cameras to take photos of the circuits. The photos are then compared to the schematic of the satellite PCB. If any mismatching is found between the photo and the schematic, the board goes for inspection under a technician.

X-Ray Inspection

X-Ray inspection is used to test the solder connections, internal traces, and barrels. It can detect hidden flaws of PCBs.

Functional Test

As the name shows, a functional test ensures the required functionalities of the PCBs.

What Are The Cooling Requirements Of A Satellite PCB?

As satellite PCBs are deployed in an extensive temperature environment in space, you must ensure an extensive cooling system for the PCBs. A satellite PCB must ensure the following cooling requirements.

Install Heatpipes Correctly To Manage The Cooling System

• Use of extensive heatsink and heat pipes. Make sure you installed them properly.
• Use extensively high-grade materials. As we mentioned before, use PTFE-based high-grade materials.
• The components must be super high-grade. Also, you need to palace them properly.
• Follow the standard manufacturing and designing steps and methods.

What Are The Significant Drawbacks Of Satellite PCB Designs?

Every good discovery has some drawbacks too. As with them, satellite PCB also has some drawbacks as well.

• Satellite PCBs are costly in terms of design, and development.
• If the frequency varies a little between the transmission and receiving, it will create an echo in the phone calls, TV signals, broadband networks, and others.
• Repairing and maintenance are costly as well.
• With natural uneven events like storms, extensive sunlight may disturb the proper signaling of the satellite.
• Continuous monitoring and maintenance is a must for the satellite once it is launched into space.

What Are The Specifications Of A Trustworthy Satellite PCB Manufacturer?

Among the other PCB sectors, satellite PCB manufacturing is the most critical, and complex task. A highly expert and skilled manufacturer can only manage satellite PCB manufacturing.

To choose this highly sensitive PCB manufacturer, you must make sure the manufacturer has the all abilities to manufacture satellite PCBs. You may check the following criteria.

• A long-time experience in the PCB manufacturing industry.
• Highly professional and skillful.
• Able to ensure the extensive technology to manufacture the PCBs.
• The staff has personal certification from proper authorities.
• IPC certification of the manufacturer.
• Material and components managing ability, as well as production ability.

What Is A PCB Assembly Solution In The Satellite Industry?

PCBMay provides extensively advanced PCB assembly services for satellite PCBs. We are able to meet the most complex, and challenging PCB design and production. We do this by using

• Cutting edge technology,
• Quick process,
• High-grade material selection, and any type of production capabilities.

We ensure the use of PTFE-based high-grade flex materials which withstand the extensive adverse environment. They are also durable for a long time.

Rigid-Flex PCB

Besides these, we ensure any type of PCBs based on the layer counts and reliability. These include,

• Flexible PCBs,
• Single-sided PCBs,
• Double-Sided PCBs,
• Multilayer PCBs,
• Rigid-flex PCBs, and
• Rigid PCBs.

Last Thoughts

Satellite PCBs are complex, highly advanced in terms of technology, and costly. However, when you have come to know about their properties, types, and work principle, it would be easy to work with satellite PCBs.

Highly skilled people and logistic support are needed to properly design and manufacture satellite PCBs. In this case, PCBMay is able to ensure the best quality and highly advanced PCBs for our valuable clients.

However, you may contact us to get the best PCBs with the best quote possible.