Multiphysics Simulation in Orbit: Targeted Control of Thermo-Structural Effects
Competition in space is intensifying, and with it, the demands placed on space systems. To stay in the race for the long term, one must pay meticulous attention to detail; after all, in orbit, success or failure often hinges on just a few micrometers. Thermally induced deformations and stresses are among the factors that are frequently underestimated. However, failing to understand temperature distributions early on risks functional failures and costly rework. Multiphysics simulation provides a decisive advantage here by making thermo-structural effects visible and manageable as early as the development phase.
Extreme operating conditions prevail in space. Components are subjected to cyclic temperature changes of up to several hundred degrees, while at the same time there is no convective cooling. This results in non-uniform temperature fields and the resulting stresses and deformations. This becomes particularly critical in precision-dependent applications such as optical systems, antennas, or precision mechanical assemblies.
When designing satellite structures, even small temperature gradients can lead to warping, which affects the alignment of optical components. Coupled thermo-structural simulation can visualize these effects—including the interactions between material, geometry, and thermal load. This allows developers to make targeted design adjustments, such as in material selection, mounting, or the thermal decoupling of individual components.
“Many problems arise not from extreme loads, but from the interplay of physical effects,” says Stefan Merkle, Dipl.-Ing. (TU), managing partner of Merkle CAE Solutions GmbH. “Simulation helps us understand precisely these interactions before they become a risk during operation.”
For example, when analyzing a satellite structure with integrated electronics, Merkle CAE was able to investigate local temperature gradients and the resulting deformations using coupled thermo-structural simulation. This demonstrated that even minor thermal inhomogeneities can lead to critical positional deviations in sensitive components. Through targeted adjustments in material selection and thermal coupling, the system behavior was significantly stabilized—even before a prototype was built.
Modern multiphysics simulations couple thermal and structural models and enable the analysis of real operating conditions—from transient temperature profiles in orbit to combined load cases from launch and operation. It is precisely this holistic approach that is crucial, as thermal effects and mechanical properties influence one another.
Suppliers also stand to gain significant value: components can no longer be viewed in isolation but must be evaluated within the context of the overall system. Simulation creates transparency at interfaces and makes it possible to tailor components to their behavior within the entire system even before integration. Against the backdrop of increasing demands for precision, miniaturization, and reliability, this approach is increasingly becoming the standard. And this is happening despite shorter development cycles and growing complexity.
Those who validate thermo-structural effects digitally at an early stage reduce development risks, improve system performance, and create a robust foundation for use in orbit. Multiphysics simulation is thus becoming a crucial tool for the next generation of space systems.
