WASHINGTON \u2014 Boeing announced it has begun 3D printing the structural panels that form the backbone of satellite solar arrays, a step the aerospace giant says will cut production times in half and help it keep pace with demand for faster spacecraft deployment.<\/p>\n
The first 3D-printed arrays will carry Spectrolab solar cells aboard small satellites built by Millennium Space Systems, both subsidiaries of Boeing\u2019s Space Mission Systems division.<\/p>\n
Solar array substrates hold solar cells in place and ensure they remain rigid and aligned to capture sunlight in orbit. They are typically built from composite panels in a process that can take weeks, with each array wing requiring extensive manual work. <\/p>\n
Boeing said in a news release Sept. 10 that the new additive manufacturing process reduces that timeline by about six months from print to final assembly, representing a production improvement of up to 50%.<\/p>\n
By printing structural elements and built-in features directly into the substrate, Boeing says it can assemble the arrays in parallel with cell production. Robot-assisted assembly and automated inspection at Spectrolab are expected to further improve speed and consistency by reducing labor-intensive handoffs.<\/p>\n
The approach is designed to scale from small satellites to Boeing\u2019s larger spacecraft platforms, including its 702-class line, with market availability targeted for 2026.<\/p>\n
\u201cBy pairing qualified materials with a common digital thread and high-rate production, we can lighten structures, craft novel designs, and repeat success across programs,\u201d said Melissa Orme, vice president of materials and structures at Boeing Technology Innovation.<\/p>\n
Additive manufacturing has become a growing part of Boeing\u2019s space and defense strategy as it seeks to trim lead times and boost production rates. The company says it has already installed more than 150,000 3D-printed parts across its portfolio, including over 1,000 radio-frequency components on each Wideband Global Satcom military satellite now in production, as well as entire structures for multiple small-satellite product lines.<\/p>\n
While 3D printing has long been used for brackets, ducts, and smaller spacecraft components, solar array substrates pose tougher challenges because they must combine ultra-low weight with rigidity and thermal stability while surviving the stresses of launch and orbit.\u00a0<\/p>\n
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