Innovative Tape Solutions that are Out of This World
This year Saint Gobain® is celebrating its 360th birthday. This milestone reflects 360 years of passion, collaboration, manufacturing success, innovation and future-focused solutions.
When we think about it, we’ve all come a long way.
360 years ago, technology as we know it was non-existent. It may have been a figment of someone’s imagination or a far-fetched story, but the reality of it was seemingly unfeasible. However, time makes all things possible.
Let’s fast forward from 1665 to 1885. This is when German engineer, Karl Benz invented the first three-wheeled motorcar. Now, fast forward to 1903. This is when the Wright brothers, Orville and Wilbur, invented the first aeroplane. Continue forward to 1969. This is when Apollo 11, a US NASA mission, landed humans on the moon.
Finally, let’s arrive at 2025. Today, more than 80 countries have a presence in space, with the US, China and Russia in the lead.
Space exploration is no longer a dream. It’s a powerful reality. It is increasingly important for international relations and is central to communications, economics and military strategies. Many of the technologies we rely on, such as GPS, weather forecasting, surveillance, and more, rely on data gathered from satellites in outer space. As scientists seek new resources and possibilities in outer space, discoveries are being made daily, including finding rare metals and water. Across all global media outlets, we hear stories of a potential manned mission to Mars.
What’s the moral of this story? The wise words of Henry Ford can sum it up: “If everyone is moving forward, the success takes care of itself.”
We’ve teamed up with Richard Austin, Global Market Manager, to explore how materials like ETFE (Ethylene Tetrafluoroethylene), FEP (Fluorinated Ethylene Propylene), and silicone work behind the scenes to help achieve success in some space-critical applications.
As the global space economy accelerates, advancements in solar technologies are becoming more crucial than ever. Solar power can play a critical role in meeting the energy demands of satellites, space exploration, military technologies and more.
Due to a unique combination of efficiency, flexibility and resilience, materials such as ETFE and FEP are poised to significantly improve solar cell efficiency, durability and adaptability. Additionally, silicones can be used in combination with ETFE and FEP to bond these materials to flexible solar cells, demonstrating excellent performance in space applications.
The concept of using solar cells in space is not at all a new one. Between 1957 and 1958, both the Soviet Union and the US began what we now refer to as the “space race,” with the launch of Russia’s Sputnik satellite in 1957, followed by the US satellite, Explorer 1, a year later. Because these satellites ran solely on battery power, they failed after only a few weeks. This prompted the US to, shortly after, launch the Vanguard 1, the first solar-powered spacecraft. Harnessing the energy of the sun, the Vanguard was able to transmit data for up to six years.
Today, the space economy continues to accelerate, and projections estimate a global market worth $1.8 trillion by 2035.
Likewise, solar technology is also rapidly advancing. Driven by the demand for flexible, durable and adaptable energy solutions, contemporary solar cells such as Global Gallium Arsenide (GaAS), Cadmium Telluride (CdTe), Copper Indium Gallium Selenide (CIGS) and amorphous silicon (a-Si) are in high demand in aerospace and military applications. Additionally, emerging solar cell technologies such as copper zinc tin sulfide (CZTS), Perovskite Solar Cells (PSCs), Organic Solar Cells (OSCs) and Dye-Sensitised Solar Cells (DSSCs) are also poised to be up-and-coming solutions for increasing efficiencies and performance in satellites, defence, consumer electronics, and other space-related applications.
Due to these advancements, the global flexible solar cell market is expected to grow at a CAGR of 25.65% during the forecasted period of 2025–2034.
Today, perhaps GaAs cells are most widely used in spacecraft and satellite power systems due to their radiation resistance and high efficiency.
So, what exactly are GaAs solar cells?
GaAs solar cells are comprised of gallium (Ga) and arsenide (As) and they are some of the most efficient solar cells — generating more power per unit area than other types of solar cells. With a higher conversion efficiency, GaAS solar cells can create more electricity per unit area of absorbed sunlight.
GaAs solar cells represent a significant advancement in photovoltaic technology — they are lightweight, durable and adaptable to various surfaces, including curved and irregular shapes. Due to these properties, their wide spectral coverage, ability to operate at extreme temperature ranges, and resistance to radiation, these cells are most commonly used in aerospace applications. For example, their:
- Reliability and high power output in demanding conditions makes them ideal for utilisation in earth observation or communication satellites;
- Temperature tolerance allows for utilisation in space probes during missions to planets with environmental extremes, such as Venus;
- Lightweight and efficiency advantages allow for utilisation within UAVs (unmanned aerial vehicles).
As highlighted earlier, beyond GaAS solar cells, there are many other widely used flexible solar cell technologies (a-Si, CIGS, CdTe, and emerging technologies CZTS, PSCs, OSCs, DSSCs).
Unlike traditional solar panels, which are rigid because they are made from glass and metal, flexible solar panels are specially designed to be lightweight, bendable and able to conform to different surfaces. Flexible solar cells are about 20% lighter than other panels. They are made using thin, lightweight, yet durable materials. When durability, lightweight properties and material resilience are critical for satellite power systems, ETFE (Ethylene Tetrafluoroethylene) and FEP (Fluorinated Ethylene Propylene) can be key considerations due to their ability to endure radiation, resist atomic oxygen exposure, withstand temperature fluctuations and extreme weather volatility.
Let’s examine this a bit more closely.
FEP has been proven to last anywhere between 3.6–5.8 years in space, under the harsh conditions of low Earth orbit, with minimal degradation. This is why it has been a premier option in applications such as within the Hubble Space Telescope. Both FEP and ETFE can help to increase solar cell efficiency due to their unique properties such as transparency, which allows maximum light transmission to the photovoltaic cell layers. With maximum light transmission, these products can help more light reach the cell to increase energy capture from a broader spectrum of wavelengths — a vital performance capability for powering the growing constellation of satellites and other space systems in orbit.
When utilised in their matte form, these materials can also reflect infrared radiation. This allows the cells to maintain thermal insulation and prevent heat-related degradation to ensure optimal functioning. Another significant advantage revolves around the self-cleaning properties of ETFE and FEP. The materials are resistant to the accumulation of dirt and dust, which can otherwise reduce the performance of solar cells. For space missions that can span years or decades (such as satellites in orbit or deep-space exploration), this is key for reducing costly and difficult maintenance and remaining efficient throughout their operational life. ETFE and FEP applications in solar cells have also been able to improve the barrier properties of front and back sheet solar cells and help filter UV wavelengths, which are known to degrade flexible solar cells. Research and development shows that implementing these material technologies into the design of modern-day solar cells helps increase longevity from 10 years to about 20 years.
Now, what about silicones?
Sometimes, silicones can serve as a bonding layer for ETFE and FEP applications. They are a highly effective combination with ETFE because neither FEP nor silicone materials will yellow over time. Additionally, silicones can be specially manufactured to have low outgassing properties and provide excellent weathering and radiation resistance.
As flexible solar cell technologies continue to evolve, materials such as ETFE, FEP and silicones will be essential for improving efficiency, durability, and performance in space-critical applications. These polymer materials are all lightweight, resistant to radiation, and capable of withstanding extreme temperature environments. These properties are vital for solar cells used in satellites and other highly demanding environments.
As the energy industry continues to strive towards more sustainable and efficient energy sources, partnerships between material suppliers and customers can help unlock the full potential of flexible solar cell technologies.
Customisation, collaboration and co-development will play a fundamental role in testing new innovative solutions, such as viable alternatives to PFAS materials, which remain unmatched in durability for space applications.
The Tape Solutions team, supported by global resources, can help you move forward and find, co-develop, or customise future-focused solutions to help you reach for the stars and achieve the next level of success. Connect with our team to start advancing energy solutions to infinity and beyond.