Thermal Management for Aerospace & Defense Electronics

Aerospace and defense electronics fail in ways commercial parts never have to survive: thermal cycling from sub-zero to high heat, sustained vibration, mechanical shock, and program lifecycles measured in decades. Hi-Rel engineers thermal management solutions built for those conditions, from DiaCool® diamond composites and CVD diamond to MoCu and WCu CuMoCu heat spreaders and base plates, matched to the semiconductor and the mission profile. Whether the application is a radar module, an electronic warfare system, an avionics package, or a satellite payload, we help engineering teams hold junction temperatures and bond-line integrity across the full operating envelope.

Thermal Challenges Unique to Aerospace and Defense

Wide-bandgap semiconductors like SiC and GaN concentrate more power into smaller die, driving up heat flux at the same time that platforms demand lower size, weight, and power. Two failure paths follow. A CTE mismatch between the die and the spreader puts repeated stress on solder and die-attach layers through every thermal cycle, leading to voiding and cracking. Insufficient conductivity lets hot spots form and shortens device life. In a fielded system that has to perform for years, neither is acceptable, which is why material selection and bond-line quality carry more weight here than in commercial designs. That’s where our products come in. 

Materials Matched to the Mission

DiaCool-Al500

For weight-sensitive avionics and space electronics, with a low 3.2 g/cm³ density and an x-ray friendly profile that supports 100% void inspection.

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DiaCool-Ag850 & Ag700

For mission-critical RF, high-power laser diodes, and photonics where peak conductivity matters most.

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DiaCool-Cu600

For power modules and microwave packages that need high conductivity with mechanical strength.

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CVD Diamond

For the most extreme power-density designs, up to 2000 W/m·K.

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MoCu & WCu CuMoCu

For traditional RF housings and power modules where predictable, proven performance is the priority.

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Built for the Defense Supply Chain 

Hi-Rel's quality systems are built around mission-critical electronics: AS9100 and ISO 9001 certifications, Nadcap™-accredited plating, ITAR registration, and RoHS/REACH compliance. Our proprietary EDM process delivers industry-leading flatness and some of the lowest voiding levels in the industry, which supports strong yields when x-ray inspection is part of a qualification or final-inspection protocol. Every part is built to be one an engineering team can trust in a fielded system.

Applications We Support

Platforms and Systems
  • Radar systems, jammers, and electronic countermeasures
  • Microwave and millimeter-wave packages, RF power amplifiers, and high-RF modules
  • Avionics and space electronics
  • High-power laser mounts and photonics
What We Manufacture

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Bring us your operating temperature range, power dissipation, package type, target CTE, and mechanical constraints, and we will recommend material options and fabrication approaches from prototype through volume.

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