As the aerospace industry embraces sustainability and cost efficiency, the intention to use advanced materials that meet both high-performance and eco-friendly standards has never been greater. In a groundbreaking collaboration, Airbus Defence and Space has joined forces with Swiss innovator CompPair Technologies to pioneer the next generation of satellite materials—bio-based composites with self-healing capabilities. This joint effort, further strengthened by the expertise of partners Bcomp and Cobratex, is poised to transform space applications by delivering materials that are not only sustainable but also offer unprecedented repairability.
The convergence of sustainability and space technology
Historically, the aerospace industry has relied on composites that, while robust, pose environmental and longevity challenges throughout their lifecycle. The shift toward bio-based composite materials marks a significant paradigm change. Derived from natural fibres such as flax and bamboo, these materials are engineered to minimise environmental impact while retaining the strength, damping, and toughness properties essential for space applications. The incorporation of such eco-friendly materials is a testament to the industry’s commitment to reducing its carbon footprint and promoting sustainability from design to end-of-life disposal.
Airbus Defence and Space, a leader in the aerospace sector, is working on a development at the forefront of this transformation. By integrating bio-based composites into its design philosophy, Airbus Defence and Space is not only advancing the technical capabilities of its satellites but also setting new benchmarks in environmental responsibility. The collaboration with CompPair amplifies this initiative by introducing a critical innovation — ultra-fast repairability through self-healing technology.
CompPair’s HealTech™: A game-changer in material repairability
At the heart of this pioneering project lies CompPair’s HealTech™ solution, a technology that endows composite materials with the remarkable ability to repair themselves in situ. HealTech™ healing is enabled by a heat trigger that repairs micro-cracks and other damage that can occur during manufacturing or due to environmental stress.
This repair property is particularly valuable in the context of satellite manufacturing operations. Traditional composite materials, once damaged, may require complex and expensive interventions that can lead to extended mission downtime or even mission failure. In contrast, CompPair’s technology can mitigate these risks by enabling repairs without the need for external intervention, thereby reducing maintenance costs and increasing overall mission reliability.
Technical merits beyond repairability
While repairability is the cornerstone of CompPair’s offering, HealTech™ composites boast a suite of technical benefits that make them highly competitive with current materials. One of the key challenges in space applications is managing outgassing—a phenomenon where volatile substances escape from materials in the vacuum of space. HealTech™ composites are expected to exhibit superior outgassing properties, ensuring that the materials remain stable and do not compromise sensitive onboard equipment.
Additionally, these composites, with natural fibres, offer enhanced demiseability after their operational life concludes, which is a critical factor in addressing space debris and environmental concerns associated with satellite end-of-life management. The inherent damping properties of these materials also contribute to the reduction of vibrations and mechanical stresses during launch and operation, further ensuring the structural integrity of satellite components.
Compatibility with natural fibres such as bamboo and flax not only reinforces the sustainability credentials of these materials but also aligns with the aerospace industry’s growing interest in lightweight, high-performance components. This marriage of eco-friendly raw materials with cutting-edge self-healing technology is setting a new standard in composite material design, promising both performance and environmental benefits.
In-orbit testing: the road to validation
To move from laboratory innovation to operational reality, in-orbit testing is scheduled for 2026: SpaceDOTS® has already been contacted and proposes both passive and active testing in orbit. This crucial phase will validate the performance of these advanced composites under real-world space conditions. The in-orbit experiments will assess the structural integrity and durability of the materials but also the effectiveness of the HealTech™ self-repair mechanism.
SpaceDOTS® offers a platform that enables precise, controlled testing of new materials in the orbital environment. Successful in-orbit validation would confirm that the composites meet the stringent requirements of space missions, paving the way for broader adoption in future satellite designs. For Airbus Defence and Space, this represents a critical step toward integrating sustainable, repairable materials into its fleet, with the potential to extend mission lifetimes and enhance overall safety.
Economic and operational benefits
Beyond the environmental and technical merits, the repairability of these composites offers substantial economic benefits. In the costly realm of space operations, any technology that reduces maintenance expenses or minimises downtime can lead to significant savings. The ultra-fast repair properties of CompPair’s HealTech™ technology translate directly into lower operational costs by obviating the need for complex, resource-intensive repairs.
Moreover, the ability to perform in-situ repairs mitigates the risk associated with micro-damage accumulation over time—a common challenge in space missions. By addressing these issues proactively, the new composite materials can help maintain optimal performance levels throughout a satellite’s manufacturing operational period, ultimately enhancing mission success rates and reducing the overall cost of ownership.
Shaping the future of aerospace materials
Uniting the visionary efforts of Airbus Defence and Space with CompPair, this collaboration represents a bold step forward in the development of sustainable, high-performance aerospace materials. By integrating innovative self-healing technology with eco-friendly, bio-based composites, the project addresses two critical challenges: environmental sustainability and long-term operational reliability. Such advancements not only challenge conventional design paradigms but also open new avenues for cost-efficient and resilient satellite systems—essential in an era where every gram counts and every mission must be flawlessly executed.
Supported by Bcomp, Cobratex, and possibly SpaceDOTS®, the deployment and in-orbit validation of these repairable composites promise to revolutionise satellite design. With CompPair’s HealTech™ technology providing the critical advantage of in-situ repairability, successful testing in 2026 could herald a new era in aerospace where sustainability and performance are inextricably linked, ensuring that future space missions are more resilient, cost-effective, and environmentally responsible.
