Blueshift Launches AeroZero® Ultra-Low Outgassing Thermal Protection Tapes to Power Lightweight Aerospace and LEO Satellite Designs

Blueshift, a technology leader in advanced thermal protection systems (TPS), has launched its new AeroZero® ultra-low outgassing Thermal Protection Tapes, a lightweight, thin, and easy-to-apply material solution that excels in extreme thermal environments – from –200°C to +2,400°C.

AeroZero® Ultra-Low Outgassing Thermal Protection Tape

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 (LEO), where satellites experience temperature swings from –170°C to +120°C every 90 minutes, up to 16 times per day.

 “With its low thermal conductivity and extreme temperature resistance, AeroZero® ultra-low outgassing TPS provide unmatched 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 over 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 whilst streamlining application time with its ‘peel and stick’ technology.

The 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 – critical for maintaining cleanliness in spaceflight and high-vacuum environments.

With surging demand from LEO megaconstellations – such as Amazon’s Project Kuiper (planned to launch over 3,200 satellites in the coming years), as well as market analysts expecting over 4,150 new LEO satellites to launch within the next five years,  the need for ultra-thin, lightweight designs under intense thermal loads will increase dramatically. Blueshift’s AeroZero® thermal tapes will enable OEMs to continue to innovate across satellites where space is often limited and temperatures fluctuate without compromising spacecraft reliability.

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

To learn more about AeroZero® Tapes, visit: https://www.blueshiftmaterials.com/az-tape/