Boeing claims breakthrough in 3D-printed solar panel component for space satellites

An artist's impression of a Millennium-built small satellite flying Spectrolab solar cells. Photo / Boeing

Boeing says it has cut production time by months on new 3D-printed solar arrays for spacecraft.

The new array approach was designed to work on small satellites and larger platforms, including Boeing 702‑class spacecraft.

The US manufacturer was targeting market availability for next year.

Boeing said by printing the panel’s structure and built‑in features, it could assemble the array in parallel with cell production.

The cells are the photovoltaic part of the array and the substrate provides the framework.

Other manufacturers and designers in this line of work include New Zealand’s RocketLab.

Boeing said robot‑assisted assembly and automated inspection at its Spectrolab subsidiary had improved speed and consistency.

It said the first 3D-printed solar arrays will fly Spectrolab solar cells on small satellites built by Millennium Space Systems, another Boeing subsidiary.

“Beyond the arrays themselves, Boeing’s approach enables a parallel build of the complete array, pairing a printed, rigid substrate with flight-proven modular solar technologies.”

The company said by printing features directly into each panel, the design replaced dozens of separate parts.

That also cut down on long‑lead tooling and delicate bonding steps with one piece that Boeing said was faster to build and easier to integrate.

Boeing called the 702 its flagship satellite model, and said it had launched more than 50 of them.

The 702 is designed to operate in geosynchronous, medium-Earth or low-Earth orbital planes.

Strike could be resolved

Meanwhile, a trade union said it reached a tentative agreement with Boeing that could resolve a strike in the aviation giant’s defence business, AFP reports.

The International Association of Machinists and Aerospace Workers Union said about 3200 workers in Missouri and Illinois would vote this Friday on a preliminary agreement including wage increases.

“We’ve found a path forward on a five-year contract offer that grows wages by 45% on average,” said Boeing vice president Dan Gillian.

Workers walked off the job on August 4 after voting down an earlier contract offer.

And Boeing said last week it was launching a recruitment drive to find “permanent” manufacturing workers to replace those on strike.

Products produced at Boeing’s St. Louis operation include the F-15 and F-18 combat aircraft, T-7 Red Hawk Advanced Pilot Training System and MQ-25 unmanned aircraft.

Last year, a much larger stoppage in Boeing’s commercial aviation business involved about 33,000 workers who halted production at Pacific Northwest factories for more than seven weeks.

- Additional reporting by Agence France-Presse