One of the technologies highlighted to us as ESA Technology Broker for the UK is a novel composite-based heat exchanger from Hycomplate Ltd. Tailored for space operations, the technology can provide lightweight and efficient thermal management for satellites, spacecraft, and cryogenic propulsion systems.
The main advantage of this technology is the combination of reduced weight with a superior heat transfer capability. Traditional metallic heat exchangers are limited by high density, corrosion risks, and limited adaptability, whereas Hycomplate’s solution boasts efficient thermal management in extreme conditions (cryogenic to high heat flux), as well as structural integration, offering strength and load-bearing capacity while serving as a thermal device.
The key concept lies in embedding thermally conductive pathways in an advanced composite matrix, engineered with carbon fibres and fillers that provide tailored thermal conductivity. The design allows for anisotropic heat transfer, enabling directed thermal control for specific mission needs.
The heat exchanger is 40–60% lighter than metallic alternatives, which means lower launch costs, as well as having a more controlled and efficient heat transfer due to the enhanced thermal conductivity. Corrosion resistant and customisable to mission-specific requirements, whether anisotropic or isotropic, the system is scalable and sustainable with an integrated functionality that combines mechanical strength with heat exchanger capability, reducing part count.
This approach offers a superior thermal performance-to-weight ratio compared to aluminium or copper heat exchangers, with potential applications including:
- Satellite avionics cooling.
- Spacecraft cryogenic hydrogen/oxygen storage and transfer systems.
- Thermal regulation of high-power electronics and sensors in orbit.
- Lightweight, multifunctional systems for future propulsion and energy platforms.
To find out more about this offering, please see here: