Blueshift to showcase lightweight thermal protection systems at SAMPE North America

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Blueshift will exhibit its portfolio of AeroZero® Thermal Protection Systems (AZ-TPS) and AeroZero Flame and Thermal Barriers (AZ-FTBs), including tapes and larger roll to roll systems, to demonstrate their performance in extreme environments at SAMPE North America.

(Seattle Convention Center, SAMPE 2026 – 27th April to 30th April)

The event provides a key platform for materials innovation within aerospace defence and advanced manufacturing sectors, making it an ideal setting for Blueshift to present its latest developments in lightweight thermal protection systems.

With increasing demand across industries such as aerospace satellites defence and high performance engineering, the need for reliable and efficient thermal management solutions continues to grow.

Addressing thermal challenges in Low Earth Orbit

One of the most demanding environments for thermal protection is Low Earth Orbit (LEO), where maintaining thermal stability is critical to spacecraft reliability and operational lifespan. Satellite components are exposed to continuous temperature fluctuations ranging from -100°C to +120°C every 90 minutes, a cycle that occurs approximately 16 times per day.

Such extreme and repetitive thermal cycling places significant strain on materials and components, often leading to degradation over time if not properly managed. Compared to traditional polyimide tapes, Blueshift’s AZ-Tapes offer a substantial performance advantage, delivering a 19 times lower thermal conductivity of 0.008 W/mK and a 6 times lower thermal diffusivity of 0.014 mm2/sec.

Thanks to their 85% air structure, these advanced materials enable engineers to design highly effective thermal barriers that reduce temperature differentials. This results in smoother and more predictable component performance, which is essential for mission critical aerospace applications.

Advanced flame and thermal barriers for aerospace and defence

For aerospace and defence applications exposed to both direct and indirect flame as well as extreme temperatures, Blueshift will also present its AZ-FTBs. This portfolio of ultra thin lightweight and flexible flame and thermal barrier solutions is engineered to deliver exceptional protection in the most demanding conditions.

One of the featured materials is capable of withstanding direct flame exposure of up to 1,100°C for 25 minutes, whilst maintaining a cold side temperature below 300°C. This level of performance highlights the material’s ability to provide critical protection in high risk environments.

The thin flexible and high performing characteristics of these barriers make them particularly suitable as an additional safety mechanism to help mitigate the risks associated with thermal runaway. This is especially relevant in applications where safety reliability and performance cannot be compromised.

Improving integration and production efficiency

Both AeroZero® TPS and FTB solutions are designed to overcome complex thermal challenges where conventional systems may fall short. A key feature of these products is their simple peel and stick application, which significantly reduces integration time and improves overall production efficiency.

This ease of use not only streamlines manufacturing processes but also supports scalability for high volume production environments. As industries continue to prioritise efficiency alongside performance, such innovations play a vital role in advancing modern engineering capabilities.

Driving innovation in thermal protection systems

Tim Burbey, Blueshift Co-Founder and President, says that SAMPE’s materials and manufacturing focus is a prime opportunity to showcase both product portfolios:

“This industry is driven by innovation, and so we are delighted with the opportunity to demonstrate how Blueshift’s leading portfolio of thermal protection systems can protect a wide range of applications and industries.

“As the industry continues to progress, we aim to not only meet standards but to help push them forward. Our products are currently in use in aerospace and beyond, so I’m excited to meet with fellow professionals to see how we can further enhance safety across these extreme environments.”

Supporting the future of aerospace and advanced manufacturing

As the aerospace and defence sectors continue to evolve, the importance of advanced thermal protection systems becomes increasingly evident. From satellite technology operating in Low Earth Orbit to high temperature industrial processes, the demand for lightweight high performance materials is set to rise.

Blueshift’s presence at SAMPE North America underlines its commitment to supporting innovation across these sectors. By delivering cutting edge thermal management solutions that combine performance efficiency and ease of integration, the company is well positioned to address the growing challenges faced by modern engineering applications.