The United States Space Force (USSF) prepares for an exhilarating launch in March 2024. USSF-62, an advanced satellite, stands poised to journey into orbit, armed with Boyd’s innovative k-Core® doubler technology. This mission involves the inaugural launch of a military Weather System Follow-on (WSF) satellite aboard a Falcon 9 rocket from the Western Range into polar orbit.

WSF-M: A Global Communication Nexus

What is WSF-M?

WSF-M: Enhancing Military Weather Monitoring

The Weather System Follow-on – Microwave satellite leverages state-of-the-art microwave technology to gather critical atmospheric and oceanic data and enables highly accurate weather forecasts, especially for expansive maritime regions. This capability bolsters military operations by furnishing essential information for informed decision-making regarding deployments, maneuvers, and strategic planning.

Boyd’s k-Core® Doubler: Empowering WSF-M Satellite Systems

Driving Success: Boyd’s Thermal Management with k-Core® Doubler

Innovate with Boyd

Drawing on decades of invaluable experience and expertise, Boyd is at the forefront of innovation designing, manufacturing, and fabricating cutting-edge thermal and engineered material solutions across diverse industries.

Our exceptional engineering, manufacturing, and testing capabilities, supported by extensive data and cutting-edge technology, empower us to develop innovative solutions tailored to specific applications. Whether it’s the k-Core® Doubler for the USSF-62 mission or K-Core® encapsulated graphite radiation panels for the DART mission, Boyd dedicates itself to driving the next generation of space missions and advancements in sectors demanding cutting-edge thermal management solutions.

Leveraging our extensive material science expertise, we actively identify the materials and components necessary to craft innovative solutions that prioritize performance, reliability, and energy efficiency. To explore the full spectrum of Boyd’s thermal and material science solutions or to discuss your project requirements in detail, visit our website or talk with our experts.

NASA’s PACE Mission is set to launch on Feb 8th with Boyd’s loop heat pipes on board. This mission is the latest highlight in Boyd’s extensive, decades long, aerospace heritage. Boyd is proud to collaborate with NASA engineers to assist in the latest space missions to help us learn more about the world we live in.

More About the PACE Mission

PACE stands for Plankton, Aerosol, Cloud, ocean Ecosystem, which are all key indicators to the health and status of Earth’s oceans and climate. PACE will be launched on February 8, 2024 on board SpaceX’s Falcon 9 payload fairings. PACE’s mission is to assess and measure the distribution of phytoplankton, tiny plants and algae that sustain the marine food web. It will also continue systematic records of key atmospheric variables associated with air quality and Earth’s climate.

Learn more about the NASA PACE Mission (NASA.gov)

More About Loop Heat Pipes (LHPs)

Loop heat pipes are a specialized thermal management component uniquely suited to both launch and microgravity environments. LHPs are a method of passive heat transport that can span over 20 meters and can resist up to 9g acceleration forces. Loop heat pipes are also flexible up to millions of cycles, meaning it can withstand any vibrational flexing or actuations over the lifespan of the LHPs application.

Learn more about our heat pipe assemblies.

Over one million known asteroids inhabit the solar system with more being discovered each day. While only a small percentage ever make it near earth, early detection and redirection of asteroids is critical for avoiding potential impact hazards.

The National Aeronautics and Space Administration (NASA) has been detecting, tracking, and developing new ways to protect against potentially dangerous asteroids for decades. Recently, they activated a revolutionary interplanetary defense program called the Double Asteroid Redirection Test (DART).

What is the DART Mission?

DART is a small spacecraft specifically designed to alter an asteroid’s path by colliding with it. The spacecraft needed to be simple and low-cost due to the disposability but function properly for the entire voyage to ensure reliable impact with the targeted asteroid.

NASA contracted Johns Hopkins Applied Physics Laboratory (APL) to create the DART spacecraft. The DART’s body was just a few feet in length and included components for navigation and propulsion that would generate extensive heat in a small, enclosed space. To avoid issues with thermal runaway and ensure reliability, a robust thermal solution was needed for heat dissipation.

Having worked with Boyd on successful projects in the past, APL reached out for help creating the radiator panels that would be affixed to the side of the spacecraft.

k-Core Encapsulated Graphite Solution

In tandem with APL, Boyd’s engineers evaluated mission requirements and performed trade studies to establish an optimized radiator design. Traditional radiator materials such as solid aluminum did not have sufficient conductance at the required budgeted mass and would add unnecessary bulk to the lightweight spacecraft. To meet the stringent thermal conductivity, weight, and durability requirements, Boyd’s engineers suggested implementing k-Core® encapsulated graphite.

k-Core® is a proprietary heat transfer system that uses encapsulated graphite within metal to significantly improve conductivity and heat spreading uniformity. k-Core® has an extensive heritage in aerospace applications due to its ability to improve performance, enhance reliability, and lower mass when compared to other materials and constructions.

After working through the overall design specifications and thermal analysis, Boyd and APL concluded that two 48″ by 24″ k-Core® aluminum encapsulated graphite radiator panels were the optimal solution. The panels went through several thermal simulations along with other vibration and durability tests to ensure that they met all project requirements. After the k-Core® radiator panels were validated, APL integrated them into the DART spacecraft for its maiden voyage.

Project Success

For the DART mission, NASA set its sights on a small asteroid called Dimorphos. On September 26th, 2022, the DART spacecraft made contact with the small asteroid. The DART team is continuing to study the results of the test, with the potential for more launches in the future.

The Boyd Difference

Boyd has decades of experience creating custom cooling, sealing, and protection solutions for mission critical aerospace applications. To learn more about our extensive aerospace capabilities or to discuss your own project needs, visit our website or schedule a consultation with our experts.