In modern aerospace engineering, every gram, degree, and micron matters. Components operating in high-temperature environments—from propulsion systems and thermal shields to electronic insulation and laser alignment modules—demand materials that combine thermal stability, electrical insulation, and mechanical reliability under extreme conditions.
Selecting the right ceramic for these applications isn’t simply a matter of temperature resistance—it’s about balancing multiple performance parameters to achieve reliable operation in harsh environments.
Insulation Under Extreme Conditions
Aerospace systems frequently operate beyond 600 °C, where metals begin to lose mechanical strength and polymers degrade rapidly. Electrical and thermal insulation become critical—especially for:
Power electronics in satellites and aircraft engines
High-voltage feedthroughs in propulsion systems
Structural supports in UHV or plasma environments
Laser and sensor mounts requiring dimensional stability
In these contexts, engineers face a dilemma: how to find a material that withstands heat, maintains insulation, and remains machinable with tight tolerances.
Key Properties to Consider
| Eigentum | Why It Matters in Aerospace |
| Wärmeleitfähigkeit | Low conductivity ensures heat isolation, protecting adjacent components. |
| Dielektrische Festigkeit | Prevents arcing or leakage under high voltages in compact systems. |
| Thermal Expansion Coefficient (CTE) | Dimensional stability ensures alignment in optical or electronic assemblies. |
| Mechanische Festigkeit | Resistance to vibration, shock, and mechanical fatigue. |
| Bearbeitbarkeit | Enables precision features and prototyping without costly diamond grinding. |
Comparing Common High-Temperature Ceramics
The workhorse of technical ceramics. Alumina offers excellent insulation, mechanical strength, and cost efficiency. High-purity alumina (>99.6%) withstands up to 1600 °Cund damit geeignet für electrical insulators, feedthroughs, and thermal spacers.
However, its brittleness and high hardness make machining complex shapes challenging.
Typical Applications: Engine control modules, electrical isolators, high-temperature sensors.
For components requiring precise geometries, Macor is often the go-to material. It combines insulating stability up to 1000 °C, near-zero porosity, and exceptional machinability—allowing designers to achieve tolerances within ±0.01 mm using standard CNC tools.
While its thermal conductivity is lower than alumina, Macor’s ability to be rapidly prototyped and joined with metals via epoxy or braze makes it ideal for optical alignment fixtures, vacuum-compatible spacers, and insulating mounts in aerospace test systems.
Wenn Formbeständigkeit is the top priority—such as in optical payloads or gyroscopic housings—low-expansion glass ceramics like Zerodur or fused silica excel. Their CTE can approach 0 ± 0.1 × 10⁻⁶ K⁻¹, ensuring minimal deformation across wide thermal cycles.
However, they have limited mechanical strength compared with alumina and are typically reserved for precision optical assemblies rather than load-bearing structures.
For aerospace electronics demanding efficient heat dissipation without electrical conduction, AlN is a standout. It combines high thermal conductivity (up to 170 W/m·K) with excellent insulation, making it ideal for power modules, LED drivers, and spacecraft electronics where weight and temperature management are critical.
The trade-off: AlN is harder to machine and typically requires diamond tooling—but for mission-critical applications, its performance is unmatched.
Choosing the Best Material for Your Application
| Anforderung | Empfohlenes Material | Hauptvorteil |
| Precise geometry, rapid prototyping | Macor | Machinable to ±0.01 mm; operates to 1000 °C |
| Maximum dielectric insulation | Al₂O₃ (99.8%) | Withstands >10 kV/mm; cost-effective |
| High thermal conductivity + insulation | AlN | Dissipates heat efficiently in power modules |
| Ultra-stable dimension control | Zerodur | Near-zero CTE for optical systems |
Precision Ceramic Manufacturing for Aerospace
Unter Jundro Keramiken, we specialize in the CNC machining of technical ceramics such as Macor, Al₂O₃, AlN, Zerodur, and Shapal-Hi-M for demanding aerospace applications.
Our multi-axis machining centers achieve:
Dimensional accuracy: ±0,001 mm
Oberflächenrauhigkeit: Ra 0.01 μm for structural parts
Flachheit: up to 1/20 λ for optical components
Every component undergoes ISO 9001-certified quality control, ensuring stable performance from prototype to flight hardware.
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