Boeing has developed a 3D-printed photo voltaic array substrate method that reduces composite construct instances by as much as six months in comparison with present manufacturing cycles. The corporate studies this represents a manufacturing enchancment of as much as 50% from print to last meeting on typical photo voltaic array wing packages. Flight-representative {hardware} has accomplished engineering testing and is transferring by means of Boeing’s commonplace qualification course of.
The 3D-printing method integrates options akin to harness paths and attachment factors immediately into every panel. This design replaces dozens of separate components, long-lead tooling, and bonding steps with a single element. “By printing options akin to harness paths and attachment factors immediately into every panel, the design replaces dozens of separate components, lengthy‑lead tooling, and delicate bonding steps with one robust, exact piece that’s sooner to construct and simpler to combine,” in keeping with the corporate.
The primary 3D-printed photo voltaic arrays will carry Spectrolab photo voltaic cells on small satellites constructed by Millennium Area Techniques, each Boeing subsidiaries. The know-how allows parallel building of full arrays by pairing printed substrates with present modular photo voltaic applied sciences. Robotic-assisted meeting and automatic inspection at Spectrolab purpose to cut back handoffs and enhance consistency.
Boeing has integrated greater than 150,000 3D-printed components throughout its portfolio, together with over 1,000 radio-frequency components on every Wideband World SATCOM satellite tv for pc at present in manufacturing. The brand new array method is designed to scale from small satellites to bigger platforms, together with Boeing 702-class spacecraft. The corporate targets market availability for 2026.
“As we scale additive manufacturing throughout Boeing, we’re not simply taking time and price out, we’re placing efficiency in,” mentioned Melissa Orme, vice chairman, Supplies & Buildings, Boeing Expertise Innovation. “By pairing certified supplies with a standard digital thread and excessive‑charge manufacturing, we are able to lighten buildings, craft novel designs, and repeat success throughout packages.”
Supply: traders.boeing.com
