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 ultimate meeting on typical photo voltaic array wing packages. Flight-representative {hardware} has accomplished engineering testing and is shifting by way of Boeing’s commonplace qualification course of.
The 3D-printing method integrates options resembling harness paths and attachment factors instantly into every panel. This design replaces dozens of separate components, long-lead tooling, and bonding steps with a single element. “By printing options resembling harness paths and attachment factors instantly into every panel, the design replaces dozens of separate components, lengthy‑lead tooling, and delicate bonding steps with one robust, exact piece that’s quicker to construct and simpler to combine,” based on the corporate.
The primary 3D-printed photo voltaic arrays will carry Spectrolab photo voltaic cells on small satellites constructed by Millennium House Methods, each Boeing subsidiaries. The know-how allows parallel development of full arrays by pairing printed substrates with present modular photo voltaic applied sciences. Robotic-assisted meeting and automatic inspection at Spectrolab purpose to scale back handoffs and enhance consistency.
Boeing has included 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 presently 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 value out, we’re placing efficiency in,” mentioned Melissa Orme, vp, Supplies & Constructions, Boeing Expertise Innovation. “By pairing certified supplies with a typical digital thread and excessive‑fee manufacturing, we are able to lighten constructions, craft novel designs, and repeat success throughout packages.”
Supply: traders.boeing.com