Green materials for electronics and advanced 2D crystal-doped technopolymers for cutting-edge Space applications

In the coming years, the space sector is expected to play an increasingly central role from economic, commercial, scientific, and geopolitical perspectives. Growing interest in space technologies, combined with rising investments from both public and private stakeholders, is projected to drive a substantial expansion of space-related activities. As a result, the space industry will need to develop materials and technologies that are more accessible, sustainable, and cost-effective, while still fulfilling the stringent reliability and durability requirements imposed by space applications. Within this framework, the present industrial Ph.D. activity, carried out in collaboration with Thales Alenia Space, was devoted to the investigation of innovative materials and advanced methodologies to support this technological transition. The research was structured into two parallel activities, focusing on sustainable materials for space electronics and on the integration of two-dimensional nanomaterials within technopolymers already qualified for space use. The first activity addressed 96,5Sn–3,0Ag–0,5Cu/electroless-nickel-immersion-gold solder joints, analysing their structural, morphological, and compositional evolution under thermal and vacuum ageing conditions representative of space environments, with the aim of assessing their long-term stability and reliability. The second activity focused on the fabrication and multi-scale characterisation of Few-Layer Graphene (FLG)-doped poly ether ether ketone (PEEK) systems subjected to thermal ageing, with the objective of tailoring their electrical and thermal properties for multifunctional applications. In parallel with the study of these material systems, a major goal of this work was the development of reusable methodologies for industrial research, qualification, and development. These studies led to the definition of a non-destructive micro-/nano- characterisation protocol, conceived as a complement to conventional destructive physical analysis (DPA) for reliability assessment, together with an established industrial workflow for the production, testing, and characterisation of nanomaterial- based systems. Overall, the results highlight the potential of lead-free electronic materials and FLG-based technopolymers for future space applications and provide experimental procedures and qualification methodologies that can support subsequent research, development, and qualification activities within Thales Alenia Space.