Boeing has announced a significant advancement in satellite manufacturing. They have begun 3D printing the structural panels for solar arrays, a move projected to halve production times and meet the rising demand for quicker spacecraft deployment.
The initial 3D-printed arrays will be integrated with Spectrolab solar cells on small satellites manufactured by Millennium Space Systems – both Boeing subsidiaries. These substrates, traditionally constructed from composite panels in a weeks-long process, will now benefit from additive manufacturing. Boeing's September 10th announcement highlights a reduction of six months in production time, achieving a 50% improvement.
The new process enables the simultaneous assembly of arrays alongside cell production. Further enhancements are anticipated from robot-assisted assembly and automated inspection at Spectrolab, reducing manual labor. This scalable approach is intended for use in both small and large spacecraft, including Boeing's 702-class line, with market availability expected by 2026.
“By pairing qualified materials with a common digital thread and high-rate production, we can lighten structures, craft novel designs, and repeat success across programs,” stated Melissa Orme, vice president of materials and structures at Boeing Technology Innovation.
This additive manufacturing strategy is a key element of Boeing’s space and defense initiatives, aimed at shortening lead times and increasing production output. Boeing reports the use of over 150,000 3D-printed parts across its projects, including over 1,000 radio-frequency components in each Wideband Global Satcom military satellite.
While 3D printing has been utilized for various spacecraft components, solar array substrates present unique challenges due to requirements for low weight, rigidity, thermal stability, and the ability to withstand launch and orbital stresses.