Boeing has developed a 3D-printed solar array substrate approach that reduces composite build times by up to six months compared to current production cycles. The company reports this represents a production improvement of up to 50% from print to final assembly on typical solar array wing programs. Flight-representative hardware has completed engineering testing and is moving through Boeing’s standard qualification process.
The 3D-printing approach integrates features such as harness paths and attachment points directly into each panel. This design replaces dozens of separate parts, long-lead tooling, and bonding steps with a single component. “By printing features such as harness paths and attachment points directly into each panel, the design replaces dozens of separate parts, long‑lead tooling, and delicate bonding steps with one strong, precise piece that is faster to build and easier to integrate,” according to the company.
The first 3D-printed solar arrays will carry Spectrolab solar cells on small satellites built by Millennium Space Systems, both Boeing subsidiaries. The technology enables parallel construction of complete arrays by pairing printed substrates with existing modular solar technologies. Robot-assisted assembly and automated inspection at Spectrolab aim to reduce handoffs and improve consistency.
Boeing has incorporated more than 150,000 3D-printed parts across its portfolio, including over 1,000 radio-frequency parts on each Wideband Global SATCOM satellite currently in production. The new array approach is designed to scale from small satellites to larger platforms, including Boeing 702-class spacecraft. The company targets market availability for 2026.
“As we scale additive manufacturing across Boeing, we’re not just taking time and cost out, we’re putting performance in,” said Melissa Orme, vice president, Materials & Structures, Boeing Technology Innovation. “By pairing qualified materials with a common digital thread and high‑rate production, we can lighten structures, craft novel designs, and repeat success across programs.”
Source: investors.boeing.com