Precision in Orbit: How Bionetics Supports NASA’s Thermal Control Systems
When it comes to spacecraft operations, thermal control is mission-critical. Whether in orbit or deep space, maintaining optimal temperatures for systems and instrumentation is essential. That’s why Bionetics Corporation, formerly Intek, Inc., plays a key role in advancing thermal and flow monitoring technology for aerospace applications.
A Legacy of Innovation in Flow and Temperature Measurement
Bionetics manufactures a full line of precision flow and temperature instruments that are defined by their thermal measurement technology. What sets these instruments apart?
- No moving parts
- Straight-through flow design
- Exceptional chemical compatibility
- High rangeability and accuracy
- Virtually maintenance-free
This unique combination makes them ideal for harsh and complex environments—including space.
Bionetics played an active role in the development of microgravity active thermal control systems. Bionetics contributed experimental flowmeters for the Temp2A-3 experiment, the first demonstration of a mechanically pumped two-phase ammonia thermal control system in microgravity which flew on STS-46 in August 1992[1]. Later, Bionetics contributed a primary and redundant ammonia flowmeter which flew on the ESA’s In-Orbit Two-Phase Experiment TPX-1 on STS-60 in 1994[2] and for TPX-II on STS 95 in 1998.[3] Bionetics Also provided a flowmeter for the Two Phase Flow (TFP) experiment’s Capillary Fluid Loop (CPL) which flew on STS-85 in 1997.
[1] https://ntrs.nasa.gov/api/citations/19930003271/downloads/19930003271.pdf
[3] ESA – Integration of TPX-II experiment in STS-95
Supporting the Active Thermal Control System (ATCS) on the International Space Station
One of Bionetics’ most notable contributions is our work on the Active Thermal Control System (ATCS) of the International Space Station (ISS). The ATCS uses liquid ammonia to manage heat generated by the station’s systems and equipment.
To monitor this flow accurately, Bionetics developed a specialized two-piece flow meter. The 1.5″ OD sensor, mounted directly on the truss system of the ISS, operates under the extreme temperature, radiation, and vacuum conditions of space. Not only does it measure flow, but it also outputs fluid temperature—leveraging Bionetics’ proprietary thermal sensing technology.
Bionetics’ expertise with aerospace sensor engineering resulted in the development of an accurate low-mass instrument that was compliant with the rigorous radiation, shock, vibration, electromagnetic interference, thermal, and vacuum conditions present in low earth orbit.
Custom Calibration Capabilities—Because Space Demands It
During development, it became clear there was no domestic calibration setup capable of validating ammonia flow at the required specifications. So, Bionetics built one. Our expertise in developing flow measurement solutions for toxic and hazardous chemicals allowed us to safely develop the custom liquid ammonia calibration test apparatus, which simulates pressurized, high-flow conditions, delivering accurate calibration at 200 to 9,000 lb/hr and 35-65°F.
This custom calibration equipment ensured the flow meters could meet NASA and Boeing’s stringent testing and performance requirements.
Clamp-On Temperature Sensors: A Simple but Powerful Innovation
In addition to flow meters, Bionetics provided custom clamp-on temperature sensors for the ATCS. These were developed at Boeing’s request, offering:
- A cost-effective backup temperature measurement
- No need to breach the fluid boundary—preserving system integrity
- High-precision readings in critical temperature ranges
- On-Orbit Installation
This solution became a valuable part of the ISS’s thermal management redundancy, ensuring continued operation even in the event of primary sensor failure.
Why Bionetics?
Whether on Earth or in orbit, Bionetics continues to push the boundaries of flow and thermal instrumentation. Our work on the ISS is just one example of how our engineering expertise, custom calibration capability, and rugged sensor design make us an indispensable partner in aerospace and beyond. Contact us for support on the next generation of in-space thermal control systems.
For more information or assistance in selecting the right flow measurement solutions, contact us today at sales-flow@bionetics.com or (614) 895-0301. Let us help you enhance the accuracy and reliability of your flow measurement systems!