Onboard Computers for Next-Generation Space Missions

CAVU Aerospace's history began in aviation before expanding into the space industry. The company's roots trace back to the United States, where two retired pilots established an aviation-related business focused on aircraft dismantling and avionics. The operation subsequently developed into an avionics repair business, building technical experience that eventually supported its entry into spacecraft electronics.

According to Manni, the company's aviation activities date back to 2002, with its involvement in the space industry beginning in 2016.

Today, CAVU Aerospace manufactures onboard computers for satellites, rockets, and spacecraft, alongside thermal control units for selected missions. Its customers include space agencies such as NASA, the Japan Aerospace Exploration Agency (JAXA), the German Aerospace Center (DLR), the European Space Agency (ESA), and the Italian Space Agency.

The company also works with satellite manufacturers, universities developing CubeSat missions, commercial launch providers, and major aerospace contractors, including Airbus.

This breadth of customers reflects the range of environments in which spacecraft computing systems must operate. A university CubeSat and a deep-space exploration vehicle may have very different processing, interface, and reliability requirements, but both depend on electronics designed to function within the constraints of a space mission.

By supplying onboard computing hardware across these applications, CAVU Aerospace occupies a specialised position within the wider spacecraft supply chain.

An onboard computer is one of the most interconnected subsystems within a spacecraft. It must communicate with other components, process information, and support the operation of the wider vehicle.

However, the precise requirements vary considerably between missions. A spacecraft carrying a camera may need specific interfaces to transfer imagery, while another mission may require numerous serial connections to manage a larger collection of instruments and payloads.

CAVU Aerospace typically develops its products around established hardware architectures, which can then be adapted to meet individual customer requirements.

Manni explains that customers often identify an existing product that covers a significant proportion of their needs, but additional engineering is usually necessary before it can be integrated into the final spacecraft design.

Because the onboard computer connects to multiple subsystems, it is frequently one of the last components to be finalised. Other equipment must first be selected and its interfaces defined, allowing the computer manufacturer to determine the exact connections, processing capabilities, and configuration required.

This creates a demanding engineering role. The computer must fit within the spacecraft's physical constraints while supporting the interfaces and operational requirements of the complete system.

For CAVU Aerospace, the challenge is to provide a flexible computing platform that can be tailored to different missions without designing every component entirely from scratch.

One of CAVU Aerospace's developments discussed during the interview is the OBC64, a next-generation onboard computer based on Microchip's PIC64 processor.

Manni describes the system as a significant step forward in onboard computing, particularly in terms of processing capability, memory, and interface support.

The development builds on CAVU Aerospace's relationship with Microchip as a design partner. Access to emerging processor technologies allows the company to begin developing compatible space hardware before the underlying components become widely commercially available.

At the time of the interview, the OBC64 was still under development and was not commercially available because the processor itself had not yet reached general commercial availability. CAVU Aerospace was working towards bringing the system to commercial readiness through its early-access programme.

The significance of this development extends beyond simply increasing computing power. Modern spacecraft increasingly need to process larger quantities of data, support more complex payloads, and manage a greater number of interfaces.

An advanced onboard computer can help accommodate these demands while providing a platform for emerging capabilities, including artificial intelligence processing at the edge.

According to Manni, the processor offers a combination of increased core capacity, radiation tolerance, and processing capability that could support a new generation of high-reliability spacecraft electronics.

Artificial intelligence is creating new opportunities for onboard data processing, particularly for missions that generate large volumes of imagery or scientific measurements.

Traditionally, satellites have often transmitted collected data to Earth for further processing. However, transferring large datasets can place demands on communications systems and limit how quickly information becomes available to users.

More capable onboard computers create opportunities to process selected information directly in orbit, depending on the mission architecture and software requirements.

Manni explains that the OBC64 is intended to bring enhanced edge-processing capabilities to spacecraft computing. Its processing resources and interfaces could support missions requiring more demanding onboard workloads, including applications involving AI.

The benefits depend on the specific mission. Earth observation spacecraft, for example, may need to handle imagery from cameras and other sensors, while scientific missions can require the processing and management of data from multiple instruments.

Increasing onboard computing capability can provide greater flexibility for these applications, although the processor must still meet the spacecraft's requirements for reliability, power, thermal management, and physical integration.

Radiation tolerance is another important consideration. Electronics operating in space must contend with radiation environments that can affect component behaviour and long-term reliability. Selecting suitable processors and designing the surrounding system accordingly are therefore essential parts of spacecraft computer development.

CAVU Aerospace's work on next-generation processing reflects a broader shift towards more capable computing architectures that can support increasingly sophisticated missions.

Although onboard computers provide a central platform for spacecraft operations, no two missions necessarily require the same interface configuration.

A satellite may need to communicate with cameras, power systems, communications equipment, scientific instruments, and other payloads. Depending on the hardware involved, these connections can use different interface standards, including SpaceWire, Ethernet, CAN, and serial communications.

Manni identifies interface capability as one of the most common reasons customers require a bespoke computer configuration.

In some cases, the number of connections required exceeds what can comfortably be accommodated on a standard board. CAVU Aerospace addresses this through additional peripheral boards or expansion cards that extend the computer's interface capabilities.

The interview includes examples of systems developed for demanding configurations, including a computer supporting six simultaneous Gigabit Ethernet interfaces and another project requiring more than 60 serial interfaces.

Such requirements demonstrate how spacecraft computing has evolved beyond the needs of simple, standalone satellites. As spacecraft incorporate more instruments and increasingly complex payload architectures, the onboard computer must support a growing network of connected equipment.

Customisation is therefore an integral part of the engineering process. Rather than forcing customers to redesign their spacecraft around a fixed computer configuration, CAVU Aerospace adapts its hardware to the needs of the wider system.

Bespoke engineering can provide the precise capabilities required by a mission, but designing every component individually can increase development time and cost.

CAVU Aerospace addresses this challenge through a combination of standardised baseboards and custom expansion hardware.

The company manufactures a limited range of core boards in quantities that are relatively large for the space industry. Customers can then add peripheral boards or expansion cards to achieve the required interface configuration, with the components assembled into a single enclosure for delivery.

This approach allows the company to retain the flexibility of custom engineering while benefiting from a degree of repeatability in manufacturing.

Manni identifies lead time as one of CAVU Aerospace's key competitive advantages. By using an established hardware foundation and adapting it where necessary, the company aims to reduce the time and cost associated with delivering specialised onboard computers.

This is particularly important in an industry where customers may be working towards fixed launch dates or operating within funding schedules that leave little room for prolonged development cycles.

The ability to combine standard hardware with mission-specific modifications can help spacecraft manufacturers secure the computing capabilities they need without starting every project from the beginning.

The growth of commercial spaceflight has significantly influenced the way satellite suppliers approach engineering and delivery.

Historically, many space programmes were led by government agencies and followed lengthy procurement and development processes. Commercial satellite manufacturers and launch providers increasingly operate under different pressures, with schedules, funding, and market competition influencing how quickly projects must progress.

Manni observes that commercial customers now expect suppliers to deliver solutions faster and more economically. This has placed greater emphasis on lead times throughout the spacecraft supply chain.

For subsystem manufacturers, the challenge is not simply to build reliable hardware. They must also be able to respond quickly to customer requirements, finalise specifications efficiently, and deliver products in time for spacecraft integration.

CAVU Aerospace's experience illustrates how these demands affect the onboard computer development process.

According to Manni, closing an order typically takes between three and six months, depending on the project. For more complex deep-space missions involving major contractors, defining the specification and scope of work can take more than a year.

Once the requirements are agreed, the manufacturer must still complete the necessary engineering, qualification, and production activities.

As the commercial market becomes more competitive, suppliers face growing pressure to improve both speed and cost efficiency without compromising the reliability required for spaceflight.

For companies such as CAVU Aerospace, repeatable hardware architectures and flexible engineering processes are becoming increasingly important to meeting these expectations.

One example discussed during the interview involves CAVU Aerospace's work with a prime contractor in Latin America developing an Earth observation constellation of approximately 40 satellites.

The project began with the development of an onboard computer and thermal control unit for the customer's first satellite.

Rather than ordering the complete constellation at once, the customer initially launched a single spacecraft to evaluate the system. This approach allowed the team to assess the satellite's performance before committing to a larger production programme.

CAVU Aerospace supported the project through several stages of hardware development and testing.

The process began with an engineering model, followed by a qualification model that underwent a series of tests designed to assess its suitability for the intended space environment. These included vibration, shock, thermal vacuum, and electromagnetic compatibility testing.

After the qualification stage, the customer proceeded with a flight model. The satellite was launched and began returning imagery, with the results encouraging the customer to expand the programme.

The subsequent production phase required modifications to the design before the hardware could be delivered in larger quantities.

The overall process took slightly more than three years, illustrating the progression from an initial engineering concept to a validated product suitable for repeated use across a satellite programme.

The project also demonstrates the value of starting with a smaller deployment before scaling up. By evaluating the first spacecraft in operation, the customer could build confidence in the design and refine its requirements for subsequent satellites.

CAVU Aerospace supports missions across a broad range of spacecraft sizes and destinations.

CubeSats remain an important part of the company's business, partly because they are relatively accessible projects and are often produced in quantities. These programmes provide a recurring market for onboard computers and other spacecraft subsystems.

At the same time, the company is contributing to more ambitious missions involving lunar and Martian exploration.

Manni explains that CAVU Aerospace is developing hardware for a Mars-related mission, although the system had not yet flown at the time of the interview. The company has also supplied onboard computing and thermal control hardware for projects associated with deep-space exploration.

The requirements for these missions can differ substantially from those of satellites operating in low Earth orbit. Spacecraft travelling farther from Earth may encounter different environmental conditions and require specialised hardware configurations to meet their operational objectives.

Nevertheless, the fundamental role of the onboard computer remains consistent: it must support the spacecraft's subsystems and operate reliably within the constraints of the mission.

For CAVU Aerospace, contributing to these projects provides an opportunity to apply its engineering capabilities across a diverse range of space environments, from compact university satellites to vehicles intended for exploration beyond Earth orbit.

The future of spacecraft engineering is being shaped by developments in launch technology, computing, and mission architecture.

Manni points to declining launch costs and the potential for larger launch vehicles to accommodate more substantial payloads. These changes can influence how spacecraft are designed, allowing mission developers to consider configurations that might previously have been too expensive or difficult to launch.

For onboard computer manufacturers, the trend creates both opportunities and continuing engineering challenges.

Even as spacecraft grow larger or incorporate more complex payloads, computers must still be designed to fit within defined limits for size and weight. CAVU Aerospace's largest onboard computers, according to Manni, remain relatively compact, with dimensions of approximately 20–30 centimetres and weights of around three to four kilograms.

At the same time, customers increasingly require greater processing capability, more interfaces, and higher reliability from their computing systems.

The expansion of lunar exploration and the development of future Mars missions also point towards a growing need for specialised spacecraft electronics.

As the industry moves towards more ambitious missions, onboard computing systems will need to evolve alongside the vehicles they support. Greater processing capacity, adaptable interfaces, and efficient manufacturing will remain important to meeting the requirements of both commercial and exploration programmes.

Onboard computers are a critical part of the spacecraft supply chain, connecting instruments, managing interfaces, and providing the processing capabilities needed to support increasingly sophisticated missions.

As the commercial space industry grows, suppliers must balance technical performance with shorter development schedules, cost efficiency, and the ability to accommodate customer-specific requirements.

CAVU Aerospace addresses these challenges through its combination of established hardware architectures, bespoke engineering, and experience supporting customers across the satellite and spacecraft industry.

Its work spans CubeSat programmes, Earth observation constellations, commercial launch vehicles, and hardware development for deep-space missions. Developments such as the OBC64 also illustrate the growing importance of advanced processing capabilities as spacecraft take on more demanding onboard workloads.

Whether supplying a standard computer, developing a custom interface configuration, or supporting a qualification programme for a new spacecraft, the company's role is to ensure that the computing hardware meets the needs of the wider mission.

As space missions continue to expand in scale and ambition, reliable and adaptable onboard computing will remain fundamental to turning spacecraft designs into operational systems.

Discover how CAVU Aerospace develops onboard computers and thermal control units for satellites, rockets, and spacecraft by visiting the company's website.

Visit CAVU Aerospace →

Watch the full SatSupply™ Insights interview with Ali Manni, Chief Engineer at CAVU Aerospace, and James Durston of Orbital Transports to learn more about spacecraft avionics, next-generation onboard processing, custom hardware development, and the evolving demands of commercial and deep-space missions.