5 Ways Fluid Control Components are Making Satellites More Reliable

Fluid control components are at the heart of nearly every primary satellite function. They’re small components that power big missions – from propellant storage and delivery to pressure regulation and thermal management.

As programs grow more ambitious, the expectations placed on spacecraft systems are reaching new heights. From Earth observation and global communications to deep space exploration, today’s satellites must operate with greater precision, longer lifespans, and minimal room for error. This evolution is driving a surge in demand for components that are not only reliable but also highly efficient and adaptable.

In this article, we’ll break down five fluid control components that play a critical role in satellite systems (and explain why they matter more than ever).

1. Isolation Valves

An isolation valve is a crucial component of a satellite, designed to remain closed even in extreme conditions. It’s often used in the gas feed system for Hall-effect thrusters (HET), which utilize gases such as xenon and krypton to guide the satellite into orbit.

A propulsion failure in orbit could render the satellite unusable or severely limit its mission. A reliable, lightweight, and reusable isolation valve helps prevent such failures by acting as a protective barrier for the tank.

2. Flow Restrictors

Fluid systems on satellites depend on precision control and repeatability. Whether you’re dividing a noble gas for anode/cathode flow or precisely metering fuel to an igniter on a chemical propulsion engine, a flow restrictor is a vital component within any satellite system. Multi-orifice flow restrictors typically demonstrate lower susceptibility to clogging than sintered restrictors, which can introduce contamination risks and may necessitate supplementary filtration.

3. Pressure Relief Valves

A is essential for preventing over-pressurization, which can damage downstream components. Without proper pressure regulation, upstream components may also be affected, potentially leading to damage or even rupture of the satellite’s tank. To maximize propellant load, systems often operate near pressure limits, making them vulnerable to unexpected spikes from overfilling or thermal expansion during different mission phases. A reliable pressure relief valve protects the system by safely venting excess pressure.

These valves are also vital for safeguarding low pressure components from over-pressurization, which can occur due to trapped propellant expansion from temperature changes, leakage, or software issues.

4. Fill and Drain Valves

In satellite systems, a plays a critical role in helping to load or purge fluids, such as propellants, pressurants, and coolants, from the tank before launch or during in-orbit refueling. These valves are also helpful during testing procedures that involve multiple fluids – for example, when proof testing using nitrogen before adding propellant.

5. Safety Screen Filters

Satellite propellant systems have very small flow paths, making contamination control especially vital. Even when using clean gases, tiny contaminants like machine debris, residue from 3D-printed parts, or component erosion can cause blockages in system flow paths. This can lead to serious consequences, including increased maintenance, decreased performance, or even catastrophic system failure.

Protecting these pathways is key to maintaining reliable operation over the satellite’s lifespan. Smaller within the system are the last line of defense to protect these components against rogue contamination.

The reliability of these components hinges not only on their design but also on the rigor of the manufacturing and quality assurance processes that support them. As satellite missions become more complex and unforgiving, the performance of fluid control components will continue to define the boundaries of what’s possible in space.

Mission success starts with reliable fluid control components

At The Lee Company, we make it our mission to solve the toughest fluid control problems in space and beyond. Our solutions are fueled by our deep heritage in space and over 75 years of engineering expertise.

We’ve delivered more than 500,000 certified parts that have supported a wide range of space missions. It’s likely that we already have the precise flow control solution you need within our extensive product line. If not, our engineers can modify our COTS components to meet your specific mission requirements without significantly increasing costs or lead times.

Standard Lee parts are designed for the cycles needed for a successful mission, whether thousands or millions. Our components are made in the U.S. and export-ready, backed by proven licensing support for ITAR, EAR, and global compliance. Each part is 100% functionally tested under a rigorous aerospace quality management system (AS9100) to guarantee performance throughout the life of the system it is installed in.

To learn more about how Lee components are used in satellite propulsion systems, explore our interactive demo.