Autonomous drones are no longer niche tech—they’re critical tools in logistics, surveillance, agriculture, inspection, and defense. These high-performance UAVs pack advanced sensors, batteries, cameras, and processors into lightweight airframes. But as electronics become more powerful and flight times grow longer, controlling heat and sealing out environmental contaminants becomes mission-critical. That’s where gaskets and thermal interface materials (TIMs) such as thermal pads come in.
Where Gaskets Are Needed Inside Drones
Drones encounter dust, moisture, vibration, and pressure changes in flight. Proper gasketing prevents failure and keeps sensitive systems operational:
-
Battery enclosures — Silicone sponge or Viton® gaskets seal against electrolyte vapor, moisture, and debris.
-
Camera and optical housings — Thin silicone foam or expanded PTFE prevents dust, water, and fogging without adding weight.
-
Flight controller & avionics bays — EMI gaskets or conductive foams can shield critical control boards from electromagnetic interference.
-
Motor pods & nacelles — Heat-resistant silicone gaskets keep out fine particulate and help manage mechanical vibration.
-
Sensor and LiDAR covers — Expanded PTFE vents balance pressure while keeping water out.
Key materials:
Silicone sponge & foam (broad temperature stability), Viton® and Viton® sponge (fuel and chemical resistance), expanded PTFE (breathable, water-resistant).
Where Thermal Pads Are Required
Lightweight yet powerful electronics in drones demand efficient thermal management:
-
Flight computers & processors — Soft thermal gap fillers (e.g., Tflex™, GAP PAD®, CHO-THERM™) bridge uneven gaps to heat sinks or chassis frames.
-
Power distribution boards & ESCs — Pads conduct heat from MOSFETs and voltage regulators to aluminum frames or heat spreaders.
-
5G & RF modules — Thin, high-conductivity pads manage hotspots in communication hardware.
-
High-lumen lighting & payloads — Pads draw heat away from LEDs or custom sensor payloads to maintain performance and life.
Popular pad choices:
-
GAP PAD® (Bergquist/Henkel) — Broad thermal range (1–6 W/m·K), ultra-soft versions protect delicate boards.
-
CHO-THERM™ & Tflex™ — Excellent softness, compressibility, and electrical isolation.
-
Graphite & ceramic-loaded pads — For very high watt densities.
Why Custom Converting Matters
Off-the-shelf pads and gaskets rarely fit the intricate geometries inside modern drones. Precision converting—waterjet, laser, or die cutting—ensures:
-
Exact fit and compression around housings and electronics.
-
Repeatable assembly for reliable field performance.
-
Optimized weight by removing unnecessary material.
At NEDC, we routinely break down large sheets of thermal pads like GAP PAD®, CHO-THERM™, and Tflex™ into small, cost-efficient runs and cut complex gaskets to exact CAD specs—helping drone design teams iterate fast and stay lightweight.