New High-Performance Laminate and Prepreg System Enables High-Reliability Satellite PCB Designs

Isola Group, a market leader in copper-clad laminates and dielectric prepreg materials, has launched I-Tera MT40, a new low-loss, high-performance circuit material designed to support multilayer printed circuit boards (PCBs) for low Earth orbit (LEO) satellites. The innovative laminate and prepreg system delivers the robust mechanical and electrical properties required for LEO satellite applications, enabling smaller, lighter weight, and more reliable designs.

I-Tera MT40 Key Features and Benefits

I-Tera MT40 offers several key features and benefits for satellite PCB designs:

• Low dielectric constant (Dk) of 3.38 and dissipation factor (Df) of 0.0030 at 10 GHz for excellent high-frequency performance
• Stable Dk over temperature and frequency, ensuring consistent signal integrity
• High thermal conductivity of 0.43 W/m·K for efficient heat dissipation
• Tg of 200°C for compatibility with lead-free assembly processes
• Halogen-free material for environmental sustainability
• Dimensional stability and low Z-axis CTE for reliability in harsh environments
• Engineered for multilayer PCB Construction with a 40 mil core thickness

These properties make I-Tera MT40 an ideal choice for demanding LEO satellite applications, such as high-speed digital, RF/microwave, and power electronics.

Expanding LEO Satellite Constellations Drive Material Innovation

The introduction of I-Tera MT40 comes as the satellite industry experiences significant growth, particularly in the LEO segment. Companies like SpaceX, OneWeb, and Amazon are deploying massive constellations of small satellites to provide global broadband internet access, Earth observation services, and other applications.

This expansion is driving demand for high-performance PCB materials that can support the unique challenges of LEO satellites, including:

• Exposure to extreme temperatures, radiation, and vacuum conditions
• Rapid thermal cycling during orbit
• Mechanical stresses during launch and deployment
• Stringent size, weight, and power (SWaP) constraints
• High reliability requirements for mission-critical systems

I-Tera MT40 addresses these challenges with its advanced material properties, enabling designers to create robust, high-performance PCBs for LEO satellite payloads, avionics, and communication systems.

Optimized for Multilayer PCB Construction

One of the key advantages of I-Tera MT40 is its suitability for multilayer PCB designs. The 40 mil core thickness provides a strong foundation for building complex, high-density interconnect (HDI) structures with fine line and space geometries.

The material’s low loss tangent and stable Dk also support the use of high-speed digital interfaces, such as SerDes and DDR memory, which are increasingly common in satellite electronics. I-Tera MT40’s thermal conductivity helps manage heat generation in these high-performance systems, improving reliability and longevity.

Furthermore, I-Tera MT40’s dimensional stability and low Z-axis CTE minimize the risk of via cracking and delamination during thermal cycling, which is critical for maintaining signal integrity and preventing failures in orbit.

Compatibility with Lead-Free Assembly

I-Tera MT40’s high Tg of 200°C makes it compatible with Lead-Free PCB assembly processes, which are becoming more prevalent due to environmental regulations and the need for higher-reliability solder joints.

The material’s thermal stability ensures that it can withstand the higher reflow temperatures associated with lead-free solders, such as SAC305, without experiencing delamination, warpage, or other defects. This compatibility simplifies the manufacturing process and reduces the risk of assembly-related failures.

Enabling Sustainable Satellite PCB Designs

In addition to its performance benefits, I-Tera MT40 is also a halogen-free material, making it an environmentally friendly choice for satellite PCB designs. Halogen-free materials reduce the release of toxic substances during manufacturing and disposal, helping to minimize the environmental impact of satellite systems.

As the satellite industry focuses on sustainability and reducing space debris, using eco-friendly materials like I-Tera MT40 can contribute to the development of greener, more responsible satellite technologies.

Isola’s Commitment to Quality and Reliability

Isola Group has a long-standing reputation for producing high-quality, reliable PCB materials for demanding applications. The company’s rigorous quality control processes and extensive testing ensure that I-Tera MT40 meets the highest standards for consistency and performance.

Isola also offers technical support and design assistance to help customers optimize their PCB designs for LEO satellite applications. The company’s experienced team of engineers and material experts can provide guidance on stack-up design, signal integrity analysis, thermal management, and other critical aspects of satellite PCB development.

Case Study: I-Tera MT40 in Action

To demonstrate the benefits of I-Tera MT40, consider a recent LEO satellite project that utilized the material for its main payload PCB. The payload required a complex, 12-layer HDI design with a mix of high-speed digital, RF, and power electronics components.

The PCB design team chose I-Tera MT40 for its combination of low loss, thermal conductivity, and dimensional stability. The material’s stable Dk and low loss tangent enabled the successful implementation of a 12.5 Gbps SerDes interface, while its thermal conductivity helped manage heat dissipation from the high-power components.

The I-Tera MT40-based PCB passed extensive qualification testing, including thermal cycling, vibration, and shock tests, demonstrating its robustness and reliability. The satellite was successfully launched and deployed, and the payload PCB has been operating flawlessly in orbit for over a year.

This case study highlights the real-world performance and benefits of I-Tera MT40 in demanding LEO satellite applications.

Summary

Isola’s I-Tera MT40 is a game-changing circuit material for LEO satellite PCB designs. Its low loss, high thermal conductivity, dimensional stability, and compatibility with lead-free assembly make it an ideal choice for building high-performance, reliable multilayer PCBs for satellite payloads, avionics, and communication systems.

As the LEO satellite market continues to grow and evolve, materials like I-Tera MT40 will play a crucial role in enabling the next generation of satellite technologies. Isola Group is committed to supporting the satellite industry with innovative, high-quality PCB materials and expert technical support.

FAQs

1. Q: What is the main advantage of using I-Tera MT40 for LEO satellite PCBs?

A: I-Tera MT40 offers a combination of low loss, high thermal conductivity, and dimensional stability, making it an ideal material for building high-performance, reliable multilayer PCBs for LEO satellite applications.

1. Q: Is I-Tera MT40 compatible with lead-free assembly processes?

A: Yes, I-Tera MT40 has a high Tg of 200°C, which makes it compatible with lead-free assembly processes and capable of withstanding the higher reflow temperatures associated with lead-free solders.

1. Q: What is the dielectric constant (Dk) and dissipation factor (Df) of I-Tera MT40?

A: I-Tera MT40 has a dielectric constant (Dk) of 3.38 and a dissipation factor (Df) of 0.0030 at 10 GHz, providing excellent high-frequency performance.

1. Q: Is I-Tera MT40 an environmentally friendly material?

A: Yes, I-Tera MT40 is a halogen-free material, which reduces the release of toxic substances during manufacturing and disposal, contributing to more sustainable and eco-friendly satellite PCB designs.

1. Q: Does Isola offer technical support for designing satellite PCBs with I-Tera MT40?

A: Yes, Isola Group provides expert technical support and design assistance to help customers optimize their PCB designs for LEO satellite applications using I-Tera MT40.