Boeing has unveiled a groundbreaking 3D-printed solar array substrate that promises to dramatically accelerate satellite production. This innovative approach is set to reduce composite build times by as much as six months, a 50% improvement over current methods.
The new technology streamlines the manufacturing process by printing features such as harness paths and attachment points directly into each solar panel. This eliminates the need for dozens of separate parts and the time-consuming bonding processes, resulting in a single, precise, and stronger component that is quicker to build and integrate.
The first satellites to feature these advanced solar arrays will be small satellites built by Millennium Space Systems, a Boeing subsidiary, and will use Spectrolab solar cells. However, the technology is designed to be scalable, with plans to implement it on larger platforms, including the Boeing 702-class spacecraft. The company is targeting market availability for this new technology in 2026.
This development is part of Boeing’s broader strategy to integrate additive manufacturing across its portfolio. The company has already successfully incorporated over 150,000 3D-printed parts in its various products, including more than 1,000 radio-frequency parts on each Wideband Global SATCOM (WGS) satellite. By leveraging 3D printing, Boeing is not only reducing production time and costs but also enhancing the performance and design of its aerospace systems.
