As LEO programs scale and timelines compress, small interface decisions can have an outsized impact on reliability, contamination control, and validation success.
In this article
- Why sealing and venting matter in LEO
- Pressure changes during ascent
- Outgassing and contamination considerations
- Thermal cycling and seal performance
- Atomic oxygen and environmental exposure
- Electronics density and EMI considerations
- Designing for test and validation
- Supporting reliable LEO programs
Among these, sealing and venting strategies play a critical role in protecting sensitive electronics, preventing contamination, and supporting long-term system performance. Environmental transitions experienced during launch and operation, such as pressure changes, thermal cycling, and exposure to reactive orbital conditions, can introduce failure modes that are difficult to detect until late in the validation process or after deployment.
Addressing these risks early helps teams improve test outcomes, reduce redesign cycles, and support mission reliability.
Sealing Devices solutions to consider (overview)
Pressure Changes During Ascent
During ascent from ground conditions to vacuum, trapped air inside enclosures can expand rapidly. Without appropriate pressure equalization, this can lead to enclosure deformation, gasket displacement, fastener stress, or compromised environmental sealing.
Effective enclosure design often requires balancing environmental protection with controlled venting to prevent pressure-induced damage while minimizing the risk of particulate or moisture intrusion.
Sealing Devices products and categories to consider
- Enclosure venting and pressure equalization vents for controlled airflow and environmental protection
- Enclosure gasketing (die-cut gaskets, silicone sponge, foam gasketing, rubber profiles)
- O-rings and flange seals for access panels, covers, and connector interfaces
- Adhesive-backed gasket materials to reduce installation variability and rework
Explore venting solutions: GORE Protective Vents
Outgassing and Contamination Considerations
In vacuum environments, certain materials can release volatile compounds that deposit onto nearby surfaces.
These deposits can impact optical payloads, thermal control surfaces, sensors, and RF components, potentially degrading performance over time.
Material screening, specification alignment, and careful selection of elastomers, foams, and adhesive systems are important steps in reducing contamination risk and supporting payload integrity.
Sealing Devices products and categories to consider
- Material selection support across elastomers, foams, and adhesives based on your contamination risk profile
- High-performance sealing materials for sensitive enclosures (application dependent)
- Adhesives and tapes chosen for cleaner assemblies and controlled bond lines
- Converted components (precision die-cuts that reduce handling, trimming, and particulates)
Thermal Cycling and Seal Performance
LEO environments expose hardware to repeated transitions between extreme hot and cold conditions. Over time, these thermal cycles can affect elastomer compression, increase compression set, and reduce sealing effectiveness.
Seal geometry, material selection, and expected mission duration all influence how sealing systems respond to these environmental stresses.
Early evaluation helps teams anticipate long-term performance rather than focusing solely on initial sealing capability.
Sealing Devices products and categories to consider
- Elastomer seals and gaskets selected for temperature swing performance (material choice depends on the full environment)
- PTFE-family and engineered sealing options for applications where elastomers are not ideal
- Foams and cushioning materials designed to maintain resilience over cycling
- Thermal interface materials for electronics assemblies where sealing and heat management interact
Atomic Oxygen and Environmental Exposure
Atomic oxygen exposure in LEO can contribute to polymer surface erosion and material degradation.
Combined with ultraviolet radiation and thermal extremes, these environmental factors may influence both sealing performance and long-term durability.
Understanding environmental compatibility during material selection supports mission life expectations and reduces the likelihood of unexpected degradation.
Sealing Devices products and categories to consider
- Material selection guidance to match polymer and elastomer families to exposure conditions
- Fluoropolymer-based options (PTFE-family components) in harsh exposure scenarios
- Protective gasketing strategies that reduce direct exposure at interfaces and seams
Electronics Density and EMI Considerations
As avionics density continues to increase, electromagnetic interference concerns frequently intersect with environmental sealing requirements.
In many applications, EMI shielding and environmental gasketing must work together to maintain signal integrity while protecting electronics from moisture, contamination, and mechanical stress.
Sealing Devices products and categories to consider
- EMI shielding gaskets and conductive elastomers for shielding plus environmental sealing at interfaces
- Conductive foams and shielding laminates for enclosure seams and access panels
- Thermal management materials that complement shielding and improve electronics reliability
Designing for Test and Validation
Thermal vacuum testing, vibration exposure, and leak verification often reveal how sealing and venting strategies perform under mission-like conditions.
Considering potential failure modes early, including compression loss, contamination pathways, and enclosure deformation, can help engineering teams avoid late-stage design changes and improve validation success.
Sealing Devices products and categories to consider
- Prototype-friendly gasket and seal builds (rapid cut gaskets, sample kits, quick-turn conversions)
- Consistent gasketing formats (adhesive-backed parts, controlled thickness materials)
- Venting solutions tailored to equalization needs without sacrificing protection
- Material traceability support for programs that require documentation consistency
Quality and verification: Sealing Devices quality systems
Supporting Reliable LEO Programs
As LEO programs continue to scale toward higher production rates, consistency, traceability, and documentation become increasingly important.
Early collaboration around materials, environmental considerations, and validation planning can help teams reduce risk while maintaining development speed.
Sealing Devices products and categories to consider
- Kitting and assembly-ready components (pre-cut gaskets, labeled kits, reduced install time)
- Preferred material standardization across programs to reduce re-qualification churn
- Supply and documentation support for repeatable builds and controlled sourcing practices
Need help selecting sealing or venting materials for a LEO application?
Sealing Devices can support your enclosure sealing, pressure equalization, EMI shielding, and thermal management needs with material guidance and assembly-ready components.
Related: GORE Protective Vents
Note: Material selection should align to your full mission environment, verification plan, and program requirements. Our on-site Applications Engineering team is here to assist.