Boeing is significantly advancing satellite manufacturing by incorporating 3D printing into the production of structural panels for solar arrays. This strategic move is expected to halve production times, a crucial development given the increasing demand for rapid spacecraft deployment.
The initial deployment of these 3D-printed solar arrays will feature Spectrolab solar cells integrated onto small satellites built by Millennium Space Systems. Both Spectrolab and Millennium Space Systems are subsidiaries within Boeing's Space Mission Systems division. Solar array substrates are essential components, providing a stable platform for solar cells and ensuring the rigidity and precise alignment needed for optimal energy capture in orbit. Traditionally, these substrates are made from composite panels through a process that can take several weeks and involves considerable manual labor.
Boeing's new additive manufacturing approach dramatically reduces this timeline by approximately six months, marking a production enhancement of up to 50%. By directly printing structural elements and integrated features into the substrate, Boeing streamlines the assembly process, allowing it to occur concurrently with solar cell production. The company also anticipates using robot-assisted assembly and automated inspection at Spectrolab to further boost efficiency and consistency.
This forward-thinking methodology is designed for scalability, accommodating a range of satellite sizes from small platforms to Boeing's larger spacecraft, such as its 702-class line. Market availability for these advanced arrays is projected for 2026. The 702-class satellites are known for their substantial power output and capacity, making them suitable for various communication and scientific missions.
Melissa Orme, vice president of materials and structures at Boeing Technology Innovation, stated, "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." This statement underscores Boeing's commitment to utilizing cutting-edge manufacturing for improved performance and design flexibility. Additive manufacturing has become a core element of Boeing's space and defense strategy, aimed at reducing lead times and increasing production rates. The company has already integrated over 150,000 3D-printed parts across its product lines, including more than 1,000 radio-frequency components on each Wideband Global Satcom (WGS) military satellite currently in production, as well as complete structures for several small-satellite product lines.
While 3D printing has been applied to smaller spacecraft components, solar array substrates present unique challenges, including stringent requirements for ultra-low weight, exceptional rigidity, and thermal stability, all while withstanding launch and orbital stresses. Boeing's innovative approach directly addresses these complexities, paving the way for more efficient and accelerated deployment of satellite solar arrays. The broader implications of 3D printing in satellite manufacturing are significant, contributing to cost reduction, enhanced material efficiency, and rapid prototyping. This technological advancement by Boeing not only streamlines its own production but also signals a wider industry shift towards agile and accelerated space asset development.