Boeing Sets Rapid Pace with 3D-Printed Solar Array Substrates

Core Insights - Boeing has introduced a 3D-printed solar array substrate that reduces composite build times by up to six months, achieving a production improvement of up to 50% compared to current cycle times [1][3]. Group 1: Production Efficiency - The new approach allows for a parallel build of the complete solar array, integrating a printed, rigid substrate with modular solar technologies [4]. - By incorporating features like harness paths and attachment points directly into each panel, the design simplifies the assembly process, replacing multiple parts and tooling with a single, precise component [5]. - Boeing has integrated over 150,000 3D-printed parts across its portfolio, resulting in significant benefits in schedule, cost, and performance [6]. Group 2: Technological Integration - The first 3D-printed solar arrays will utilize Spectrolab solar cells on small satellites produced by Millennium Space Systems, showcasing the collaboration within Boeing's Space Mission Systems [3][7]. - The production process includes robot-assisted assembly and automated inspection, which enhances speed and consistency in manufacturing [7]. Group 3: Market Impact - The new solar array technology is designed to scale from small satellites to larger platforms, including Boeing 702-class spacecraft, with market availability targeted for 2026 [7]. - Boeing's advancements in additive manufacturing not only reduce time and costs but also enhance performance, enabling the company to produce more efficient and innovative designs [6].