Radiation-hardened semiconductors for satellites to be developed by BAE Systems

BAE Systems got $16 million in defense funding to develop space-ready microchips. The funding will be used to demonstrate and qualify its RH45 radiation-hardened 45-nanometer (nm) semiconductor technology. Space has an extreme environment. Without the buffer of Earth’s atmosphere, radiation-heavy environments can ruin standard microelectronics in seconds. To keep satellite brains from melting in orbit, the US government aims to design tough chips. Behind the $16 million funding is a key mission: validating BAE’s proprietary RH45 chips and unlocking a secure, onshore hardware catalog for defense builders. Hence, it is a big win for onshore manufacturing. Why silicon breaks in orbit Commercial microchips are fast, tiny, and cheap, but are also exceptionally fragile. A single stray high-energy proton in deep space can flip bits, corrupt code, or permanently burn out a processor. Several radiation-induced incidents have also occurred in the past, and it is one of the leading causes of satellite anomalies and mission failures. For instance, Russia’s ambitious mission Phobos-Grunt (2011), intended to retrieve soil samples from Mars’ moon Phobos, was stranded in Earth orbit shortly after launch. Several reasons were stated for the failure. Among them, one was that heavy ions from cosmic radiation struck unhardened, commercial off-the-shelf (COTS) microchips, corrupting the computer memory and causing a fatal system reboot. Nowadays, commercial chips continue to shrink, which make them far more sensitive to tiny electric charges. Hence, space agencies and defense contractors use specialized manufacturing techniques like Radiation Hardening (Rad-Hard) or Silicon-on-Insulator (SOI) layers to insulate chips and dissipate unwanted electrical charges. Built with specialized insulation and design tricks, these tech take cosmic hits and keep computing. The technology is essential. Without it, modern space missions fail The newly funded project relies on GlobalFoundries’ manufacturing facility in Malta, New York, using 45nm SOI technology. By bringing fabrication back to American soil, the DOW reduced reliance on complex overseas supply chains for sensitive defense hardware. Hardening the microchips to make them radiation-proof The RH45 Storefront functions like an advanced digital hardware store. Space agencies and defense contractors can take pre-tested, radiation-resistant building blocks and assemble custom Application-Specific Integrated Circuits (ASICs) tailored to their exact needs. It gives engineers creative freedom without forcing them to reinvent the wheel every time a new satellite launches. “Design flexibility is important when it comes to supporting space missions,” said Joe Dziezynski, Space Systems product line director at BAE Systems. “Our RH45 ASIC library is a unique and trusted capability that allows our customers to target specific functions while meeting radiation-hardened requirements.” These high-performance microchips power a wide spectrum of space operations. Deep-space planetary probes rely on them to execute complex autonomous navigation and real-time sensor processing billions of miles from ground control. National security assets use the radiation-resistant architecture to safeguard vital defense payloads, maintaining unbroken surveillance, threat detection, and encrypted military communications. Meanwhile, commercial orbiters integrate these components to maximize operational uptime for weather-tracking networks and global satellite telecommunications. The chips are already heading to hardware. BAE is baking the RH45 technology directly into its next-generation Endura Single-Board Computers, creating high-speed, low-power processing units built specifically for orbit. Final assembly, packaging, and testing will take place at BAE’s Space Systems facility in Manassas, Virginia — an accredited Category 1A Microelectronics Trusted Source. Get the latest in engineering, tech, space & science - delivered daily to your inbox.Mrigakshi is a science journalist who enjoys writing about space exploration, biology, and technological innovations. Her work has been featured in well-known publications including Nature India, Supercluster, The Weather Channel and Astronomy magazine. If you have pitches in mind, please do not hesitate to email her.