Boeing has developed a 3D-printed photo voltaic array substrate method that reduces composite construct occasions by as much as six months in comparison with present manufacturing cycles. The corporate stories this represents a manufacturing enchancment of as much as 50% from print to remaining meeting on typical photo voltaic array wing applications. Flight-representative {hardware} has accomplished engineering testing and is shifting via Boeing’s commonplace qualification course of.
The 3D-printing method integrates options equivalent to harness paths and attachment factors straight into every panel. This design replaces dozens of separate elements, long-lead tooling, and bonding steps with a single part. “By printing options equivalent to harness paths and attachment factors straight into every panel, the design replaces dozens of separate elements, lengthy‑lead tooling, and delicate bonding steps with one sturdy, exact piece that’s sooner to construct and simpler to combine,” in accordance with the corporate.
The primary 3D-printed photo voltaic arrays will carry Spectrolab photo voltaic cells on small satellites constructed by Millennium House Programs, each Boeing subsidiaries. The know-how permits parallel development of full arrays by pairing printed substrates with current modular photo voltaic applied sciences. Robotic-assisted meeting and automatic inspection at Spectrolab intention to scale back handoffs and enhance consistency.
Boeing has included greater than 150,000 3D-printed elements throughout its portfolio, together with over 1,000 radio-frequency elements on every Wideband International SATCOM satellite tv for pc at the moment 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, vp, Supplies & Buildings, Boeing Expertise Innovation. “By pairing certified supplies with a typical digital thread and excessive‑fee manufacturing, we will lighten constructions, craft novel designs, and repeat success throughout applications.”
Supply: buyers.boeing.com