Boeing Revolutionizes Solar Array Production with 3D-Printing
Boeing's Innovative 3D-Printed Solar Array Substrates
Boeing has recently introduced a groundbreaking approach in aerospace technology with its 3D?printed solar array substrates. This innovative method significantly cuts down composite build times by up to six months on a typical solar array wing program. Compared to current cycle times, Boeing is achieving a remarkable production improvement of up to 50%.
Advancements in Engineering Testing
Flight-representative hardware has successfully completed rigorous engineering testing and is currently progressing through Boeing's standard qualification path. This is an essential step as the company prepares its technology for upcoming customer missions.
Efficiencies and Technological Integration
“Power sets the pace of a mission. We reached across our enterprise to introduce efficiencies and novel technologies to set a more rapid pace,” said Michelle Parker, vice president of Boeing Space Mission Systems. By integrating Boeing's additive manufacturing expertise, along with Spectrolab's advanced solar technology and Millennium’s efficient production line, the team is enhancing the speed of production, enabling customers to deploy resilient constellations at an accelerated pace.
First Solar Arrays with Spectrolab Technology
The initial batch of 3D-printed solar arrays, which will feature Spectrolab solar cells, will be installed aboard small satellites produced by Millennium Space Systems. These subsidiaries are integral parts of Boeing's Space Mission Systems organization.
Redefining Array Construction
One of the vital aspects of Boeing's unique approach is the ability for a simultaneous build of the complete array. This method combines a printed, rigid substrate with proven modular solar technologies. By incorporating features like harness paths and attachment points directly within each solar panel, Boeing's design streamlines the process, eliminating the need for multiple separate components, long-lead tooling, and complex bonding steps. The result is a single, robust, and precise piece that is faster to produce and easier to assemble.
Performance Enhancement Through Additive Manufacturing
“As we scale additive manufacturing across Boeing, we're not just cutting costs; we're enhancing performance,” explained Melissa Orme, vice president of Materials & Structures, Boeing Technology Innovation. The strategic combination of qualified materials, a digital production thread, and high-rate assembly can lead to lighter structures, innovative designs, and consistent success across various programs.
Significant Integration of 3D-Printed Parts
Boeing has effectively integrated over 150,000 3D-printed parts into its portfolio, which offers substantial benefits in scheduling, costs, and performance. This includes implementing more than 1,000 radio-frequency parts on each Wideband Global SATCOM (WGS) satellite currently under production.
The new solar array approach is adaptable, designed to work efficiently on both small satellites and larger platforms, including Boeing's 702-class spacecraft. Efforts are underway to ready this innovative technology for market availability by 2026.
By 3D printing both the structure of the panels and the integrated features, Boeing enhances its capability to assemble the arrays concurrently with the production of solar cells. Additionally, the use of robotic assembly and automated inspection at Spectrolab minimizes the need for manual interventions, thereby contributing to greater speed and consistency in production.
Boeing's Commitment to Innovation
As a leading global aerospace company and a top exporter from the United States, Boeing is dedicated to developing, manufacturing, and servicing commercial airplanes, defense products, and space systems for clients in over 150 countries. The company's workforce and supply chain are pivotal to driving innovation, fostering economic opportunities, and promoting sustainability and community impact. Boeing is steadfast in its mission to uphold a culture embedded in core values such as safety, quality, and integrity.
Contact Information
Zeyad Maasarani
Boeing Communications
+1-562-400-5533
Boeing Media Relations
SOURCE Boeing
Frequently Asked Questions
What recent technology did Boeing introduce?
Boeing introduced a 3D?printed solar array substrate that enhances production efficiency and reduces build time significantly.
How much time can be saved in production?
Boeing's new approach can reduce composite build times by up to six months compared to traditional methods.
Who are the partners involved in this technology?
The technology involves collaborations between Boeing, Spectrolab, and Millennium Space Systems for the production of solar arrays.
What are the benefits of the 3D printing approach?
The 3D printing method reduces the number of parts, streamlines assembly, and enhances consistency while lowering costs.
When will the new solar arrays be available?
Boeing aims to have market availability for the new solar arrays by the year 2026.
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