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Aerostar International
1814 “F” Ave
Sioux Falls, SD 57104
Tel: (605) 331-3500
Fax: (605) 331-3520
E-mail: sales@aerostar.com

© 2008 Aerostar International
All Rights Reserved
In association with:
BFA, BBAC, NACDA,
IFAI, PIA, IAAPA & IFEA

High Altitude Scientific Balloons



I would like more information on High Altitude Research Balloons

The materials used to construct
modern scientific balloons consist of
plastic film and fiber tapes.

The plastic film makes up the shell
of the balloon while the polyester fiber
load tapes provide the strength in the structure and allow it to carry
such heavy loads.

The polyethylene plastic films range
in thickness from 6 µ to 25 µ with
the most common thickness
being 20µ
(about the same as
a sandwich bag).





To fabricate the balloons, layers of film
are laid out on a pattern on tables up to
213 m long. A large scientific balloon
can have over 150 gores.

The edges of the sheets are sealed
together using a specially designed,
proprietary heat sealer.

Once the sheets are sealed together
along the edges of the pattern,
they form "gores" and the load
tapes are applied to the seals at
the edges of the gores.


Using current materials technology, balloon
flights are possible in the area below the
dashed line on the chart.

Small balloons are used to carry light to
medium weight payloads to high altitudes.

These missions tend to be oriented
more toward atmospheric sciences.

Hundreds of Aerostar balloons are used
each year in the study of the ozone layer
at both the northern and southern polar
regions to monitor the chemical
mechanisms responsible for
ozone hole formation each year.






NASA uses Aerostar small balloons for very
high altitude wind profile soundings.

These balloons carry a GPS sonde to altitudes
up to 130,000 feet to obtain wind profiles
before a large scientific balloon mission.

Plastic balloons reach high altitudes more
reliably than rubber weather balloons
because the balloon envelope does
not stretch as the system ascends.

The flaccid balloon is filled with just enough
helium to lift the payload and balloon plus
about 20% "free lift". As the balloon
ascends, the lifting gas inside –
usually helium – expands to inflate
the rest of the balloon.

The balloon materials do not experience any appreciable stress until the balloon as fully
inflated at its peak altitude.

Small Balloon Accessories

Small balloons can be flown in two different modes: as sounding balloons, or as
zero pressure balloons. Sounding balloons ascend until the balloon becomes
fully inflated and then burst. Zero pressure balloons are equipped with ducts to
equalize the pressure at the base of the balloon creating a zero pressure
differential at the bottom of the balloon. At full inflation, the zero pressure balloons
enter a neutrally buoyant state at a constant altitude.

The zero pressure balloons are used for longer duration flights. Following are
the suggested and required accessories for the two different types of flights:

Sounding: No accessories necessary unless a burst panel is desired.

Burst Panel: A rectangular piece of film that is slightly weaker than the
surrounding balloon envelope material. It is located at the top of the balloon to
assure a rapid deflation of the balloon at burst altitude. Balloons without a burst
panel can deflate more slowly and take longer to reach the ground.

Zero Pressure: The required accessories are a channel duct and a destruct device

Channel Duct: A part of the base material in the balloon is left open to the
atmosphere to allow gas to escape once the balloon is fully inflated. This allows the
balloon to reach an equilibrium altitude.

Destruct Device: A rip panel installed at the top of the balloon which is attached
to a rip chord that passes through the base of the balloon to the payload. As the
payload is released from the base of the balloon, the rip panel is torn open and
rapidly deflates the balloon.

High Altitude Balloon Performance Charts

Performance charts are provided for zero pressure balloons and for sounding
balloons in Aerostar’s standard sizes. Please contact us if you do not see a size
which fits your requirements.

We are a custom manufacturer, able to size or design a balloon to fit your
exact needs.

Zero Pressure Balloons.pdf

Sounding Balloons.pdf

I would like more information on High Altitude Research Balloons