Spacecraft electronics are vulnerable to damage from temperature extremes, impacts, and long missions. Traditional PCBs cannot repair themselves after cracks or fractures, risking total mission failure.

This invention introduces self-healing PCB circuits using embedded microfluid channels underneath the electrical traces. If a trace fractures, conductive liquid metal flows into the break and restores the circuit automatically.

How it works:

During PCB fabrication, tiny channels are built into the FR4 material right under the copper traces. These channels are filled with a conductive liquid, such as Galinstan. If a crack occurs, the fluid flows into the gap through natural capillary action, instantly repairing the trace without any external commands.

What makes it novel:

Unlike older methods that use capsules or backup circuits, this system is fully integrated into the PCB layers. No pumps, no complex sensors, and no redundancy are needed. It is lighter, simpler, and perfect for space missions where repairs aren’t possible.

How it would be produced:

The channels are created using existing PCB manufacturing methods like laser micromachining. The liquid is injected after the board is made. It only needs minor changes to current factory processes, making it scalable and cost-effective.

Where it would be applied:

• Satellites
• Deep space probes
• Lunar rovers
• Space station modules
• Flight avionics for spacecraft

Market potential:

Space agencies and private space companies are launching thousands of satellites and deep-space missions. Reducing failure risks by self-healing electronics could save billions in lost hardware and missions.

Cost comparison:

Compared to adding backup circuits or extra shielding, this self-healing system saves weight and manufacturing cost while improving mission reliability.