In avionics, thermal management solutions are integral to safe and efficient operations. They serve to ensure sensitive electronics remain within temperature limits, prevent hotspots that could degrade reliability, and help extend component life—even under extreme thermal cycling and vibration.
T‑Global USA specializes in advanced thermal interface materials (TIMs) that are engineered for flight‑critical systems. To help your team navigate these challenges, we’ve created a practical guide to cooling avionics—covering how our TIMs ensure consistent quality, prevent outgassing, and maintain stable performance when it matters most.
The Thermal and Environmental Challenges of Avionics
Harsh Operating Conditions
Many flight-critical systems and equipment endure harsh operating conditions. Inclement weather, repeated exposure to rain, and other factors can degrade systems over time, with extreme temperature fluctuation potentially occurring in these environments. Thermal interface materials offer a wide range of operating temperatures from -50°C to +200°C, serving to keep systems functioning optimally, especially for integrated circuits.
Limited Space and Weight Constraints
Aircraft systems demand strict weight reduction for fuel efficiency, while avionics components are densely packed, leaving minimal room for traditional heat sinks or bulky cooling solutions. To address these challenges, T-Global provides custom-cut thermal pads, adhesive backing options, and specialized post-processing services designed to fit complex geometries and confined spaces. These solutions ensure optimal thermal performance without compromising design flexibility or weight requirements.
High Heat Loads Dissipation
Dissipating high heat loads is another challenge, particularly when managing extreme temperature fluctuations. Even reducing operating temperatures by a few degrees can significantly add to a device’s service life and performance. These advantages make it important to implement effective thermal management for avionics systems that can help maintain stable operating temperatures.
Specialized TIM Solutions for High-Reliability Avionics
Choosing thermal interface materials for your application involves balancing thermal performance with strict constraints on weight, power, and cost. To meet the specific needs of avionics systems, T-Global offers multiple TIM solutions that adhere to this industry’s tight standards. Our selection includes the following:
- Ultra-soft thermal pads. To protect highly sensitive components and systems, you may want to use ultra-soft thermal pads, which T-Global can provide in both silicone and silicone-free versions based on your specific cooling requirements. These products consist of ultra-soft materials and a range of tackiness levels, with the ability to reduce operating temperatures while providing sufficient physical protection. To fit limited spaces and complex designs, we also offer custom cutting methods, adhesive options, and additional post-processing services for thermal pads.
- Graphite films. Natural and synthetic graphite sheets can be used that optimize both thermal conductivity and flexibility. Their thermal conductivity varies based on the specific requirements of their structure and manufacturing process. Thin and lightweight options are available from T-Global for use in compact devices operating at high power levels.
- Silicone-free thermal putty. Silicone-free thermal putty offers enhanced protection for electronics and other equipment in aircraft. Using silicone-free materials can help minimize outgassing, or the release of contaminating volatile compounds like silicone oil, making it an environmentally friendlier option, as well.
- Thermal tapes. Another option available at T-Global is our selection of high-viscosity thermal tapes, which can fill gaps and dissipate heat by transferring it to heat sinks. This option may work better for your system if you need a reliable adhesive.
The Assurance of Custom Thermal Engineering and Testing
Custom thermal management interfaces that are engineered for specific thermal and environmental conditions help avionics companies meet stringent industry requirements. T-Global provides highly dependable TIM solutions that utilize standard methods for testing and engineering to ensure reliable operation of aircraft systems. As a result, our customers benefit from top-quality supplies that offer superior performance, with experts behind them who understand the specific requirements of aircraft systems in challenging environments.
Turn to T-Global for Thermal Management for Avionics
If you’re searching for the best available thermal interface materials, from silicone-free thermal compounds to graphite films, we can help you maximize your systems’ longevity and performance. Choose from our full range of product options, which we can customize based on your individual requirements. We also offer additional solutions that can help you get the most from our products, including custom thermal modules, cutting and other post-process solutions, and testing services that adhere to internationally recognized standards. We share your commitment to quality, environmental responsibility, and material safety for demanding applications.
Submit your request today for a quote or a sample! We’ll be ready to match you with the right solution.