Addressing Reliability Gaps in Low Earth Orbit Electronics
Electronics operating in low Earth orbit (LEO) face some of the most demanding reliability requirements of any industry. Satellites, missiles, and spacecraft must survive extreme thermal cycling, vibration, and environmental exposure for years, without the possibility of repair once deployed.
During a recent interview at APEX Expo 2026, Ginny Hogan of Dymax discussed how conversations with OEMs revealed a persistent materials gap in space electronics. Many legacy adhesives were grandfathered into programs even though they did not meet modern performance expectations or current MIL-STD-883 requirements. In response to this long standing need, Dymax developed 9773, a UV curable adhesive designed specifically for LEO applications.
Dymax 9773 features low ionic content and low outgassing, which are critical for long-term mission reliability in space environments. The material has been tested across a wide operating temperature range from –65°C to +125°C to withstand large fluctuations.
The adhesive is used as a staking material to ruggedize capacitors on printed circuit boards. By securing components and absorbing mechanical energy, the material helps prevent damage caused by vibration and movement during launch and operation. The application typically involves dispensing one or more beads from the top of the capacitor to the PCB, with the number determined by the component's height and width. In certain situations, the material can also function as an encapsulant.
The light-curable formulation enables curing in seconds, eliminating the need for racking or stacking, and aids manufacturing efficiency in high-reliability electronics. While well-suited for larger components, engineers must consider component size and mass, as heavier materials may not be appropriate for very small structures such as fine gold wires.
Ginny also emphasized the growing importance of low outgassing materials across all electronics, including increasingly miniaturized consumer devices, where outgassing and redeposition can impact long term performance. Dymax offers complementary solutions, such as the 9771 conformal coating, to support broader reliability requirements in space and defense electronics. Both materials have been deployed on satellites since November 2023, reflecting rising demand for modern materials designed to meet today's space mission challenges.