Turning Problems into Solutions: Engineering for space applications

Last year, a customer approached us with a highly customized request for a large-format Kapton heater integrated with Sheldahl aluminized polyimide for light reflection for use in a space application. Although we noted challenges, we also saw opportunities to push our engineering to a new level.

The Challenge: Pushing the limits

This project had two unique challenges. One, the requested heater was substantially larger than our standard production range. Two, the heater needed to be fitted with Sheldahl aluminized polyimide, a material with outstanding reflective qualities. Unfortunately, we also soon discovered that the Sheldahl material scratched much too easily, creating an unacceptable risk to product quality and customer satisfaction. These dual requirements posed challenges in both scale and material sensitivity, demanding new innovative solutions from our team.

The Response: Thinking outside the box

To address the size limitation, we took a modular approach. We manufactured the heater in three sections and then joined them with custom wiring. A precision FR4 fixture was developed in-house to ensure accurate alignment before patching the jumper areas and seams. This enabled us to maintain the integrity and shape of the final assembly.

To protect the Sheldahl surface, our QC team ran a series of tests to identify materials that could be safely used to protect the material during handling. We discovered that a film already available in our facility precisely fit our needs. We are able to mask the Sheldahl with this film throughout the production process and thereby ensured the material’s appearance and performance remained pristine.

The Result: A high-quality solution

The result was a large, high-performance Kapton heater that met every aspect of the customer’s original specification. More importantly, we proved once again that Birk’s engineering agility and commitment to quality can turn any challenge into a success story.

Looking ahead

This project shows what truly sets Birk Manufacturing apart: deep technical expertise, agile problem-solving, and a commitment to delivering uncompromising quality. Faced with size restrictions and material limitations, our team responded with precision, creativity, and collaboration. When customers bring us complex or unconventional requirements, Birk Manufacturing designs and manufactures successful solutions every time.

Reach out to find out how Birk’s engineering team can support your projects.