What’s the Forecast: Weather Satellite Technologies
Weather forecasting uses scientific principles, mathematical models, and knowledge of past weather patterns to predict future weather patterns. While forecasts are dependent on human analysis, interpretation, and judgment, the increasing sophistication of data collection continues to improve accuracy. Satellites have become an essential tool in this process and connector components are integral to their success.
GOES-U, the fourth and final weather satellite in NOAA’s GOES-R series, launched on June 25, 2024, and is in operation over the East Coast of North America. Now known as GOES East, it provides advanced weather imagery, atmospheric measurements, and real-time mapping of lightning activity, as well as critical space weather observations. The satellites in the GOES (Geostationary Operational Environmental Satellites)-R series provide crucial data for weather forecasting, severe storm tracking, and climate monitoring. Their advanced instruments and rapid updates improve detection of atmospheric phenomena like hurricanes, wildfires, and lightning, which aids the National Weather Service and meteorologists in early warnings, disaster preparedness, and resource management.
“GeoXO (Geostationary Extended Observations) will expand on the GOES-R weather series to help NOAA provide better, more accurate information on severe weather patterns, marine ecosystems, air quality, and our changing climate,” said Anthony Dimercurio, deputy chief engineer for GeoXO at Lockheed Martin. “With new instruments onboard, the constellation will bring many new advancements, including the first geostationary observations of our coastal ecosystems that supports resilient coastal communities, near real-time hyperspectral sounding to map the state of the atmosphere, enhanced lightning observations for severe convection monitoring, and continental U.S.-wide observations of harmful pollutants in the air we breathe.”
Electronics in space
“Space applications often require custom electronics solutions with specific attention given to the unique conditions, so it is important to understand what is needed from the start,” said Travis Neumann, special projects manager at Omnetics Connector Corporation. In space, for example, SWaP (size, weight, and power) is a major issue, especially as many companies have migrated to low earth orbit (LEO) nanosatellites, or CubeSats. Multiple small satellites can be launched in a constellation and are more cost effective than a single large version but make size and weight constraints even more critical.
“Connectors and the accompanying harnesses enable electrical signals to reach their required destinations, from the tiniest CubeSat, which may have 10 or less connectors, up to a large spacecraft like GeoXO that will have hundreds of connectors,” said Dimercurio.

Connectors for CubeSats from Omnetics Connector Corporation
“When considering power and signals, current dictates the size of the conductors where voltage can affect spacing. Once we know how many of these connections we need, we can use that number, along with the voltage or current rating of those connections (or signal in terms of speed) to determine the best solution,” said Neumann. “In addition, there is a transition from the traditional large military connectors, into high reliability micro and nano types. Technology used in servers, such as blade mount or stackable connections, promotes assembly of large constellations. Users of wired solutions are looking into flex circuits as a space-saving option for better management of the harness and connections between boards in their CubeSats.”
Harsh environment challenges
Designing electronic components that can withstand the rigors of space is an important part of the process. Vibrations and large shocks to the satellite’s body structure, known as pyrotechnic shocks or pyroshocks, can occur when the satellite separates from the launch vehicle. Pyroshocks can be detrimental to circuit boards and short electrical components. Connectors and harnesses may become displaced from the circuit boards causing electronic devices to fail.
“Radiation in space makes shielding necessary, however, shielding adds weight so that becomes a factor,” said Neumann. “Materials should also be chosen with a wide enough operating temperature range to prevent fatigue from repeated hot/cold cycles.”
Outgassing is another consideration, particular for optical imaging systems. Optical sensors often have lenses with very tight cleanliness requirements. Dimercurio explained that cadmium plating, for example, is a very common finish type on flight connectors because it is a rugged material that protects against corrosion, which is a significant factor at Cape Canaveral due to Florida’s high humidity. “Unfortunately, cadmium also sublimates in a vacuum. This means that cadmium molecules will separate from the connector finish and can end up attaching to the optical lenses of our instruments. This would obviously pose a big problem [for the mission],” he said.
A tight RF seal between the connector and the component it is attached to is also critical. ”If there are any gaps, however miniscule, it is an opportunity for RF signals, particularly data lines that switch hundreds of millions of times a second, to ‘leak’ and be picked up by GeoXO comm instruments,” said DiMercurio.

Materion supplies materials for weather satellites. AlBeMet (left) aluminum-beryllium MMC (metal matrix composite) is used for satellite structures. It combines the benefits of aluminum and beryllium metals for greater design flexibility, specific stiffness, and performance advantages over titanium, aluminum, and conventional aluminum MMCs. It is also used for thermal management in satellite electronics. SupremEX MMC (right) combines an ultrafine silicon carbide reinforcement with aerospace aluminum alloys into composites that are superior to conventional alloys because they combine the lightweight properties of aluminum with outstanding strength and stiffness.

Materion’s high-purity beryllium S-200-F metal is used in many satellites because it allows for volume and weight reductions without a loss in durability. It has a high heat resistance and thermal stability in the cryogenic temperatures found in space.

Materion’s QMet alloy, the gold standard material, combines copper, chromium, and silver. It has shown greater conductivity than all other alloys of similar strength with sharp formability, and stress relaxation resistance comparable to that of copper beryllium. For design engineers, the extra conductivity will allow them to create high current and high heat transfer components for smaller spaces than ever before, which is extremely valuable on satellites.
Environmental monitoring
Satellite technology goes beyond weather forecasting to address environmental challenges and aid disaster response efforts. The Sentinel-1C satellite launched from Kourou, French Guiana, aboard the Vega-C rocket on December 5, 2024. The third in the Sentinel-1 mission, it collected critical data for environmental monitoring and sent initial radar images of Svalbard, Norway, the Netherlands, and Belgium within its first week in orbit. Working with Sentinel-1A, launched in 2014, Sentinel-1C will provide data for monitoring earthquakes, volcanic activity, landslides, deforestation, and changes in polar ice. Radar, rather than an optical system, allows the satellite to gather information in all weather conditions, day or night.

Smiths Interconnect supplied Hyperboloid Contact Technology CMD series PCB connectors (left) and spring probe interposers (right) to the Sentinel-1C satellite. Their reliability and durability make them ideal for demanding space environments. The spring probe interposers provide excellent signal integrity and mechanical resilience and improve miniaturization allowing removal of cable harnessing inside the system. Both solutions play a key role in the radar transmission systems to track and transmit the satellite position.
The Sentinel-1 mission is part of the Copernicus Programme (the Earth Observation component of the European Union’s space program) managed by the European Commission and supported by European Space Agency (ESA). Smiths Interconnect worked with contractor Thales Alenia Space. “Our hyperboloid and spring probe solutions, along with our circulators, are designed to withstand the harsh conditions of space and ensure consistent performance,” said Julian Fagge, president at Smiths Interconnect.
To learn more about the companies mentioned in this article, visit the Preferred Supplier pages for Omnetics Connector Corporation, Smiths Interconnect, and Materion Corporation.
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