Very light and ultra-stiff carbon fiber composite structures are the standard for demanding structures in the space industry.
15 years of experience in space travel
Ultra-rigid structures for the harsh conditions in space
Project-specific solutions according to customer requirements
Coefficient of Thermal Expansion (CTE) in CFRP, tailored through fiber orientation for maximum dimensional stability
Typical Build Volume for Space Structures at Connova
The Connova Group has also been active in space travel for over 15 years. With our lightweight and highly rigid composite components, we increase the payload capacity of launch vehicles and build structures for particularly light satellites and spacecraft. We have a broad space heritage and impress with project-specific solutions.
We have many years of experience in the development and production of space structures made of composite or titanium components. Regardless of whether particularly high mechanical or special thermo-mechanical requirements are required for the harsh conditions in space – our engineers already know the solution or are developing it together with the customer.
Our portfolio ranges from satellite primary structures and high precision telescope frames to reusable launcher components. Every component is engineered for its specific mission and developed by Connova from concept through to flight qualified hardware.
The main load bearing structure of a satellite, serving as the structural backbone to which all subsystems are attached. Manufactured from CFRP or titanium composite hybrid materials, featuring qualified bonding processes and integrated inserts for subsystem interfaces. Connova manufactured, among others, the complete primary structure for the ESA Aeolus Aladin satellite (STM and PFM models).
High precision CFRP support structures for space telescopes, including tube geometries, spider structures, and optical benches. Micrometer level stability across thermal cycles.
High precision CFRP platforms for scientific instruments. Structural baseplates for optical components with micrometer level tolerances.
Mounting structures for primary and secondary mirrors, ranging from large telescopes such as the Giant Magellan Telescope to satellite optics.
Structural components for launch vehicles and reusable launchers. Themis landing legs serve as a reference for the next generation of Ariane launch vehicles.
GFRP and CFRP structures for antennas, high frequency components, and electromagnetically transparent applications.
In space, material selection determines mission success. Vacuum, cosmic radiation, thermal cycles from -150 °C to +120 °C, and extreme vibration loads during launch all require different fiber and matrix combinations.
Choosing the right manufacturing process is just as important as selecting the right material. We offer the full range of manufacturing technologies in house and select the most suitable process for each project based on geometry, production volume, and performance requirements.
As specialists for composite material solutions in space travel, we offer an extensive portfolio of services: from consulting and product development in the space sector to the design and analysis of space components and the optimization of space systems.
Thanks to our many years of expertise in the production of high-performance composites for space travel, our experts ensure the most effective manufacturing method for your space product, always maintaining the highest quality standards and reliable delivery.
We offer a wide range of CNC services specifically for model making, mold making and final machining of composite components in the aerospace industry, always with a 100% guarantee of accuracy.
We offer a comprehensive range of machining and support services that can serve as an integral part of the manufacturing process of your aerospace composite components, as well as provide complementary support for your own manufacturing.
Our components are used in key European space missions, ranging from Earth observation and exoplanet research to planetary defense. Due to confidentiality agreements, specific component scopes are often undisclosed. The programme categories below illustrate the breadth of our expertise and the diversity of the platforms we support.
Every space project follows the same four stage process. This ensures a seamless path from the initial concept to qualified flight hardware, with a single point of contact throughout all project phases.
Technical analysis, material selection, and manufacturing strategy. Initial effort and timeline estimation.
FEA simulation, lay-up optimization, and tooling concept. Load and lifetime verification.
First article manufacturing, FAI documentation, material testing, and non-destructive testing (NDT).
Manufacturing under EN 9100, continuous quality monitoring, and on time delivery.
Swiss engineering and space composites are a natural fit because both demand uncompromising precision. These four differentiators make the difference in European space procurement.
Recognized ESA supplier with more than 15 years of heritage in key European space missions.
Especially in the space environment, success depends on making the most of the unique strengths of each material.
Every process step and every material batch is fully documented throughout the entire lifecycle of the component.
From material sourcing and finishing to laminates, assembly, precision machining, inspection, and bake-out, everything is provided from a single source.
Head of Sales & Project Management, Connova Group
Taylan Toprak is a graduate aerospace engineer (TU Munich, graduated in 1993) with over 30 years of experience in aerospace engineering. As Head of Sales & Project Management at the Connova Group, he is responsible for business development and project management – including in the space segment, where the company has been active for over 15 years. The Connova Group supplied composite structures for the ESA CHEOPS mission and is developing CFRP landing legs for reusable launch vehicles (Themis/Almatech).
Why you benefit from his expertise:
“Spaceflight demands absolute reliability at minimum weight. With the Connova Group’s over 15 years of space experience and my personal background in aerospace engineering, we guide our customers from concept to flight-qualified hardware.” — Taylan Toprak, Head of Sales & Project Management, Connova Group
Project Lead Space Structures · Connova Group
Over 10 years of experience manufacturing high precision CFRP structures for space applications. Responsible for telescope structures and optical baseplates, including current projects such as Comet Interceptor (CoCa Baseplate), CO2M (telescope structure), and RAMSES/CHANCES (telescope structures for the Apophis companion mission).
In addition to our standard ISO 9001 certification, we proudly maintain our higher level EN9100 quality management certification for the aerospace industry. We guarantee controlled, measurable quality from material procurement to delivery of the end product. With our high-precision testing equipment, we meet the highest industry standards. Trust us when it comes to precision and consistent quality assurance.
In the development and production of a complete primary structure made of CFRP/titanium (STM and PFM models), the Connova Group supported ESA with the material selection, the manufacturing concept and a specially qualified bonding process with specially developed bonding gauges.
Other services:
Connova Group not only provided support with fiber composite-specific designs, but also with the production of large, thick-walled CFRP parts. We combine different manufacturing processes and meet the highest requirements regarding the accuracy of the mold surfaces. We carried out the complete CNC finishing using large-scale machining machines.
Connova Group was responsible for the precise and distortion-free production of highly rigid, thick-walled and absolutely straight structural parts and was also responsible for process validation and process control. There was also precise CNC machining.
Discover how Connova Group plays a key role in developing revolutionary landing legs for the Themis T1H launch vehicle. This case study highlights the breakthrough technologies and outstanding manufacturing processes that make the dream of reusable rockets for space exploration a reality. Download the full case study now to learn more about this fascinating journey into the vastness of space!
The Connova Group was responsible for the development of the manufacturing processes and the production of four complete landing legs for a demonstrator of a future launch vehicle as part of the Themis project.
The project, commissioned by Almatech and ArianeGroup, aims to develop technologies for cost-effective, reusable rockets to be operational after 2030 as the successor to Ariane 6.
The Connova Group developed and manufactured high precision CFRP mirror mounts (bezels) for the Giant Magellan Telescope (GMT), one of the most ambitious scientific projects of our time. The exceptional dimensional stability and low coefficient of thermal expansion of carbon fiber composites are essential for maintaining the precise positioning of the optical components throughout all temperature cycles. Located at the Las Campanas Observatory in Chile, the GMT features a primary mirror composed of seven segments, making it one of the world’s largest telescopes. Commissioning is planned for the early 2030s.
Space composites are advanced fiber-reinforced materials, typically carbon fiber reinforced polymers (CFRP), qualified for operation in the space environment. They combine minimum weight with exceptional specific stiffness and proven performance under vacuum conditions, cosmic radiation, and thermal cycling.
ESA SME is the designation awarded by the European Space Agency to small and medium-sized enterprises qualified to supply European space programs. Connova has maintained this status for many years, enabling direct contracting with ESA as well as Tier 1 integrators such as Thales Alenia Space and Almatech.
We work with the full spectrum of aerospace-qualified composite systems, including standard-, intermediate-, and high-modulus carbon fibers (e.g., M40J, IM7), glass fibers for radome applications, matrix systems ranging from epoxy resins to BMI and cyanate ester, as well as sandwich structures with Nomex® or aluminum honeycomb cores.
Low Outgassing refers to the requirement that materials release only minimal amounts of volatile substances when exposed to vacuum. In space, these substances could contaminate sensitive optical surfaces, including mirrors, lenses, and detectors, potentially compromising mission performance. We qualify our material systems according to the ESA standard ECSS-Q-ST-70-02.
Our standard component size for space structures is approximately 1.5 m³. For flat geometries, larger lengths and widths are also possible with composite manufacturing.
The complete set of 10 questions with detailed answers can be found in the accompanying briefing document.
A reference glossary of the most important terms in space composite engineering, useful for procurement, project management, and technical evaluation.
A composite material made of carbon fibers embedded in a polymer matrix. The standard material for space structures, offering exceptional specific stiffness.
A composite material made of glass fibers embedded in a polymer matrix. The standard material for radome related and electromagnetically transparent applications.
European Space Agency status for recognized SME suppliers in European space programmes.
Aerospace Quality Management System standard based on ISO 9001, with additional aerospace specific requirements.
The release of volatile substances in a vacuum. Critical due to the risk of contaminating optical surfaces. Standard: ECSS-Q-ST-70-02.
High-temperature thermoset matrix system. Service temperature up to ~230 °C, used for engine area and high-temperature aerospace applications where epoxy is insufficient.
A measure of how much a material changes in length per unit of temperature. In CFRP, the CTE can be tailored through the laminate lay-up, making it critical for optical stability.
Documented verification that a manufactured part meets all engineering and quality requirements. Mandatory step before transitioning from prototyping to certified series production.
Documented inspection of the first article to verify compliance with all specifications. A mandatory step before series production.
Inspection methods (ultrasonic testing, X-ray, thermography) performed without damaging the component. Mandatory for primary structures.
A construction consisting of two composite face sheets bonded to a honeycomb core (Nomex® or aluminum), providing the highest stiffness-to-weight ratio.
Performance requirements for aircraft cabin interiors: low flame spread, low smoke emission, and low toxicity.
Mit grosser Expertise, gewonnen aus zahlreichen Projekten im Bereich des Leichtbaus über mehrere Jahrzehnte, stehen wir bereit, Ihre Visionen zu realisieren. Kontaktieren Sie uns für ein professionelles Beratungsgespräch, in dem wir gemeinsam erörtern können, wie wir als Ihr potenzieller Partner fungieren können. Unser Beratungsservice ist selbstverständlich kostenlos und ohne jegliche Verpflichtung für Sie.
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