Networking at a High-Altitude

Challenge: Networking where no network has gone before

Aerostar previously relied on Ubiquiti Edge Routers, but end-of-life hardware and growing demands for port density, lower power consumption, and environmental durability necessitated a new solution.

Aerostar’s high-altitude operations present unprecedented networking challenges:

• Extreme temperatures
  Flights routinely encounter temperatures ranging from -40°C to -80°C, well beyond the capabilities of standard commercial routers.
• Limited payload space
  Routers must be compact and lightweight to fit within specialized balloon frames or UAS platforms.
• High reliability
  Networking hardware must remain operational for months with no maintenance, powering payloads via solar panels and batteries.
• Complex connectivity
  The systems require multiple Ethernet ports, VPN capabilities, and support for a variety of network protocols to handle telemetry, command-and-control (C2), and real-time data streaming.
  
  

Solution: Local LAN, global reach, no matter how high you fly

Aerostar deployed the Netgate 2100s, leveraging pfSense software, for high-altitude and remote networking.

Beneath each balloon sits a payload frame carrying critical instruments. On 90% of balloon flights, Aerostar deploys a router just as you would in any standard network. Recently, they’ve paired a Starlink Mini with the router, providing a WAN interface while all payload devices connect via a local LAN.

The 2100s were paired with industrial-rated switches as needed, creating a modular, mission-ready networking solution suitable for one-time-use balloon flights or longer-duration unmanned aerial missions.

Key features included:

• Extreme temperature performance
  The 2100 successfully operated in the vacuum chamber, testing down to -80°C, well beyond typical commercial hardware specifications.
• Low power consumption
  At 4 watts, the 2100 reduced power requirements compared to previous hardware, a critical factor for solar- and battery-powered payloads.
• Compact Design
  Its small size and lightweight design allowed it to be integrated into balloon payload frames without affecting flight dynamics.
• Flexible connectivity
  Four LAN ports enabled local networking for payload sensors and instruments, while WAN and VPN capabilities ensured secure communications.
• Open-source flexibility
  pfSense Plus enabled customization to meet specific telemetry and routing requirements unique to each flight mission.
  
  

“Each payload is fully self-contained, powered by solar energy during the day and battery reserves at night, operating for months in the stratosphere with no external power or physical access.”

- Aaron Wyant, Aerostar International LLC

Results & Benefits: Reliable connectivity at the edge of the stratosphere

With the Netgate 2100, Aerostar achieved:

• Reliable networking in extreme environments
  Routers maintained operation at stratospheric altitudes with temperatures as low as -80°C for almost a one-year mission
• Reduced payload power and weight
  Lower power consumption and a compact form factor optimized balloon flight efficiency.
• Scalable deployment
  Modular design enables quick integration across diverse UAS and balloon platforms.
• Enhanced mission capability
  Secure, real-time telemetry and command-and-control for NASA instrumentation, government communications, disaster response, and commercial monitoring.
• Future readiness
  Support for the upcoming TAA certification ensures broader deployment potential across government and commercial missions.

About Aerostar

Netgate is proud to support a partner committed to making the world more connected and secure.

Aerostar represents the evolution of innovation in action, building on decades of lighter-than-air expertise to become a leader in high-altitude platforms and advanced manufacturing. Today, Aerostar leverages cutting-edge technology, such as the Netgate 2100 in stratospheric systems, to connect, protect, and support critical missions worldwide, from communications relay to life-saving applications, as it continues to push the boundaries of what’s possible at 70,000-plus feet.

Aerostar has taken lighter-than-air technologies to all new heights by leveraging the most brilliant minds, materials, and machinery for over 70 years to connect, protect, and save lives. Their platforms support NASA, government, and commercial applications worldwide, delivering innovative solutions for data collection, communications, and disaster response.

Learn more about Aerostar

About Netgate

Netgate develops pfSense software-based routers that deliver enterprise-grade networking, security, and flexibility across commercial, government, and remote applications.

About the Netgate 2100 with pfSense Plus

The Netgate 2100 is a compact yet powerful security gateway appliance that pairs purpose-built hardware with the pfSense Plus software platform, delivering enterprise-grade firewall, routing, and VPN capabilities in a small desktop form factor. Designed for homes, remote workers, and small business networks, it features a dual-core ARM Cortex‑A53 CPU, 4 GB DDR4 RAM, and flexible Ethernet connectivity (WAN RJ45/SFP combo plus four LAN ports).

The Netgate 2100 proves its versatility by powering high-altitude balloon payloads and connecting Starlink Mini WAN interfaces to onboard LAN networks, while withstanding extreme temperatures and altitudes. pfSense Plus offers advanced firewall filtering, VPNs, multi-WAN load balancing, IDS/IPS, and detailed traffic management, all managed via an intuitive web interface. With passive cooling, low power draw, and expansion options for additional storage, the Netgate 2100 is a small device capable of delivering reliable, scalable, and secure networking, even at the edge of the stratosphere.

Learn more about the Netgate 2100 with pfSense Plus