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Advanced thermal protection systems (TPS) company  (Spencer, Mass., U.S.) has launched AeroZero ultra-low outgassing thermal protection tapes. The lightweight, thin and easy-to-apply material solution excels in extreme thermal environments from –200°C to +2400°C.

In the vacuum of space, thermal challenges are amplified. Satellites, spacecraft and instruments are exposed to intense, repeated thermal cycling — especially in low Earth orbit, where satellites experience temperature swings from –170°C to +120°C every 90 minutes, up to 16 times per day.

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“With its low thermal conductivity and extreme temperature resistance,  ultra-low outgassing TPS provide protection in these demanding environments — all without adding weight or bulk,” says Tim Burbey, president of Blueshift. “Our customers needed a solution that could survive brutal heat swings in very tight spaces. We delivered an ultra-thin, high-performance thermal tape that fits in narrow design envelopes, then optimized it for ultra-low outgassing when spaceflight standards required it. It’s a perfect match for next-gen LEO satellites and beyond.”

Already proven in more than 10,000 ft² of deployed spacecraft, AeroZero tapes are engineered to mitigate extreme thermal cycling in orbital and high-vacuum environments, thus preserving sensitive optics and sensors by reducing fogging, degradation and interference. This makes the tapes ideal for satellite platforms, including optics, sensors, infrared detectors and vacuum chamber systems, used across the aerospace and defense industries. Furthermore, due to their lightweight, thin and flexible format, the AeroZero tapes can be applied to tight configurations while streamlining application time with its “peel and stick” technology.

AeroZero thermal tapes also minimize contamination risk by meeting the NASA Outgassing Standard (ASTM E595), ensuring that no more than 1.0% total mass loss and 0.10% condensable material is released under high vacuum and elevated temperatures, which is critical for maintaining cleanliness in spaceflight and high-vacuum environments.

Blueshift has released two AeroZero low-outgassing thermal tapes, 1O2 and 1O4, each providing an adhesive that is tailored to fit specific performance needs.