Designing electronics for space is a fundamentally different discipline than designing for terrestrial applications. On Earth, we take for granted stable temperatures, atmospheric pressure, magnetic field protection from radiation, and the ability to physically access hardware for repairs. In space, none of these exist.
At Upper, we leverage over a decade of ground-based robotics and embedded systems experience to design computing platforms that survive and operate reliably in the most demanding environment there is.
The Space Environment
Before discussing design principles, it’s worth understanding what makes space so hostile to electronics:
Radiation. Beyond Earth’s magnetosphere, electronics are bombarded by cosmic rays and solar particle events. A single heavy ion can flip a bit in memory (single-event upset), latch up a circuit (single-event latch-up), or permanently damage a transistor (single-event burnout). Over time, total ionizing dose degrades semiconductor performance and eventually causes failure.
Thermal extremes. In low Earth orbit, a satellite transitions between direct sunlight (+120°C) and Earth’s shadow (-170°C) every 90 minutes. Components must survive thousands of these thermal cycles without cracking solder joints, delaminating PCBs, or failing from thermal fatigue.
Vacuum. Standard electronics rely on convective cooling — heat rises through air. In vacuum, the only thermal dissipation paths are conduction (through the structure) and radiation (emitting infrared). This fundamentally changes thermal management strategy.
Vibration. Launch vehicles subject payloads to intense vibration and acoustic loads during ascent. Every solder joint, connector, and component mounting must survive this mechanical environment.
Design Principles
Our approach to space-rated embedded system design follows several core principles:
Radiation Mitigation
We employ multiple strategies depending on the mission profile and radiation environment:
- Component selection — using radiation-tolerant or radiation-hardened parts for critical functions, with commercial-off-the-shelf (COTS) parts where appropriate with additional mitigation
- Error detection and correction — ECC memory, TMR (triple modular redundancy) for critical logic, and scrubbing routines for FPGA configurations
- Shielding — strategic placement of mass around the most sensitive components, balanced against the weight budget
- Software watchdogs — automated detection and recovery from radiation-induced anomalies
Thermal Management
Without convection, thermal design becomes a conduction and radiation problem:
- Thermal interface materials — ensuring efficient heat transfer from components to the spacecraft structure
- Heat pipes and cold plates — passive thermal transport for high-power components
- Heater circuits — keeping components above their minimum operating temperature during eclipse periods
- Thermal modeling — FEA-based simulation of the full thermal environment before hardware is built
Power Efficiency
Solar panels generate limited power, and batteries have finite capacity. Every watt matters:
- Low-power processor selection — choosing architectures that deliver maximum computation per watt
- Dynamic power management — scaling clock frequencies and shutting down unused peripherals based on the current mission phase
- Power budgeting — allocating and tracking power consumption at the subsystem level throughout the design lifecycle
From Ground to Orbit
One of Upper’s key strengths is that our space embedded systems design builds on proven ground-based robotics architectures. Many of the same principles apply — our ground vehicles also operate in extreme temperatures, high vibration, and remote environments where maintenance is impossible. Space takes these constraints to their logical extreme, but the engineering discipline is the same.
This means our space designs benefit from battle-tested ground software, proven communication protocols, and reliable sensor interface patterns — adapted and hardened for the orbital environment.
What We Deliver
Our space embedded systems services cover the full design lifecycle:
- Requirements analysis and mission-specific trade studies
- Schematic design and PCB layout for space-rated boards
- Radiation analysis and mitigation strategy
- Thermal modeling and management design
- Firmware and flight software development
- Environmental testing support (thermal vacuum, vibration, radiation)
If you’re developing a spacecraft, satellite, or launch vehicle and need reliable embedded computing, contact us to discuss how we can support your mission.