Boeing Sets Rapid Pace with 3D-Printed Solar Array Substrates
Boeing (NYSE: BA) has introduced an innovative 3D-printed solar array substrate technology that significantly reduces production time by up to 50%, cutting build times by up to six months for typical solar array wing programs. The technology has completed engineering testing and is advancing through Boeing's qualification process.
The new approach combines Boeing's additive manufacturing expertise with Spectrolab's solar technology and Millennium's production capabilities. The 3D-printed design integrates features like harness paths and attachment points directly into panels, replacing numerous separate parts and simplifying assembly. The technology will be implemented first on small satellites and is scalable to larger platforms, with market availability targeted for 2026.
Boeing (NYSE: BA) ha presentato una nuova tecnologia di substrato per pannelli solari stampata in 3D che riduce drasticamente i tempi di produzione fino al 50%, accorciando i tempi di realizzazione fino a sei mesi per i comuni programmi di ali con array solare. La tecnologia ha superato i test ingegneristici ed è in fase di qualificazione presso Boeing.
Il nuovo approccio unisce l'esperienza di Boeing nella produzione additiva con la tecnologia solare di Spectrolab e le capacità produttive di Millennium. Il progetto stampato in 3D integra percorsi per i cablaggi e punti di attacco direttamente nei pannelli, sostituendo numerosi componenti separati e semplificando l'assemblaggio. La tecnologia sarà prima adottata su microsatelliti ed è scalabile a piattaforme più grandi, con disponibilità sul mercato prevista per il 2026.
Boeing (NYSE: BA) ha presentado una innovadora tecnología de sustrato para paneles solares impresa en 3D que reduce significativamente los tiempos de producción hasta en un 50%, acortando los plazos de fabricación hasta seis meses para los programas típicos de alas con matrices solares. La tecnología ha completado las pruebas de ingeniería y avanza en el proceso de cualificación de Boeing.
El nuevo enfoque combina la experiencia de Boeing en fabricación aditiva con la tecnología solar de Spectrolab y las capacidades de producción de Millennium. El diseño impreso en 3D integra rutas de cableado y puntos de fijación directamente en los paneles, reemplazando numerosas piezas separadas y simplificando el ensamblaje. La tecnología se implementará primero en satélites pequeños y es escalable a plataformas mayores, con disponibilidad en el mercado prevista para 2026.
Boeing (NYSE: BA)는 생산 시간을 최대 50%까지 크게 단축하는 혁신적인 3D 프린팅 태양광 어레이 기판 기술을 선보였습니다. 이 기술은 일반적인 태양광 날개 프로그램의 제작 시간을 최대 6개월까지 단축합니다. 해당 기술은 엔지니어링 테스트를 완료했으며 Boeing의 인증 절차를 진행 중입니다.
새로운 접근 방식은 Boeing의 적층 제조 전문성과 Spectrolab의 태양광 기술, Millennium의 생산 역량을 결합합니다. 3D 프린팅 설계는 패널에 하네스 경로와 장착 지점을 직접 통합하여 여러 개의 분리된 부품을 대체하고 조립을 단순화합니다. 이 기술은 소형 위성에 먼저 적용되며 대형 플랫폼으로 확장 가능하고, 시장 출시 목표는 2026년입니다.
Boeing (NYSE: BA) a présenté une nouvelle technologie de substrat d'array solaire imprimée en 3D qui réduit significativement les délais de production jusqu'à 50%, raccourcissant les temps de construction jusqu'à six mois pour les programmes d'ailes avec arrays solaires typiques. La technologie a achevé les tests d'ingénierie et progresse dans le processus de qualification chez Boeing.
Cette approche combine l'expertise de Boeing en fabrication additive avec la technologie solaire de Spectrolab et les capacités de production de Millennium. Le design imprimé en 3D intègre des chemins de câblage et des points d'attache directement dans les panneaux, remplaçant de nombreux composants distincts et simplifiant l'assemblage. La technologie sera d'abord déployée sur de petits satellites et peut être déployée à plus grande échelle, avec une disponibilité commerciale visée pour 2026.
Boeing (NYSE: BA) hat eine innovative, 3D-gedruckte Substrat-Technologie für Solaranlagen vorgestellt, die die Produktionszeit erheblich um bis zu 50% verkürzt und die Bauzeiten bei typischen Solarrumpf-Flügelprogrammen um bis zu sechs Monate reduziert. Die Technologie hat die Ingenieurtests abgeschlossen und durchläuft die Qualifizierungsprozesse bei Boeing.
Der neue Ansatz vereint Boing's Kompetenz in der additiven Fertigung mit der Solartechnik von Spectrolab und den Produktionskapazitäten von Millennium. Das 3D-gedruckte Design integriert Kabelwege und Befestigungspunkte direkt in die Paneele, ersetzt zahlreiche separate Bauteile und vereinfacht die Montage. Die Technologie wird zunächst bei Kleinsatelliten eingeführt und ist auf größere Plattformen skalierbar, mit Marktverfügbarkeit geplant für 2026.
- Production time reduction of up to 50% for solar array manufacturing
- Simplified manufacturing process by replacing dozens of separate parts with single integrated components
- Technology is scalable from small satellites to larger Boeing 702-class spacecraft
- Successfully completed engineering testing and progressing through qualification
- Market availability not until 2026, indicating a relatively long commercialization timeline
Insights
Boeing's 3D-printed solar array substrates cut production time by 50%, enhancing spacecraft manufacturing efficiency and competitive positioning in the space sector.
Boeing's new 3D-printed solar array substrate technology represents a significant manufacturing breakthrough with tangible operational benefits. By compressing composite build times by up to six months (a
The technology's value comes from its elegant simplification of the manufacturing process. By printing features like harness paths and attachment points directly into panels, Boeing eliminates dozens of separate parts, long-lead tooling requirements, and delicate bonding procedures. This integration creates a single, strong, precise component that accelerates production and simplifies integration.
What makes this particularly valuable is the cross-enterprise collaboration between Boeing's additive manufacturing expertise, Spectrolab's solar technology, and Millennium's production capabilities. This integrated approach enables parallel construction of complete arrays, pairing printed rigid substrates with existing modular solar technologies.
The scalability from small satellites to larger 702-class spacecraft platforms indicates this isn't a niche application but a foundational manufacturing advancement. With target market availability in 2026, Boeing is positioning this technology as a competitive advantage in the rapidly growing space industry where production speed increasingly determines market success.
This development builds on Boeing's broader additive manufacturing strategy, which has already incorporated over 150,000 3D-printed parts across its portfolio. The robot-assisted assembly and automated inspection further enhance quality while reducing production time - a significant advancement in space manufacturing technology that strengthens Boeing's position in the competitive space systems market.
Flight‑representative hardware has completed engineering testing and is progressing through Boeing's standard qualification path ahead of customer missions.
"Power sets the pace of a mission. We reached across our enterprise to introduce efficiencies and novel technologies to set a more rapid pace," said Michelle Parker, vice president of Boeing Space Mission Systems. "By integrating Boeing's additive manufacturing expertise with Spectrolab's high‑efficiency solar tech and Millennium's high‑rate production line, our Space Mission Systems team is turning production speed into a capability, helping customers field resilient constellations faster."
The first 3D-printed solar arrays will fly Spectrolab solar cells aboard small satellites built by Millennium Space Systems. Both non-integrated subsidiaries are part of Boeing's Space Mission Systems organization.
Beyond the arrays themselves, Boeing's approach enables a parallel build of the complete array, pairing a printed, rigid substrate with flight-proven modular solar technologies.
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. It is built upon the foundation of Boeing's qualified additive, flight-proven materials and processes.
"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. That's the point of enterprise additive, it delivers better parts today and the capacity to build many more of them tomorrow."
Across the Boeing portfolio, the company has incorporated more than 150,000 3D‑printed parts, yielding significant schedule, cost, and performance benefits. This includes more than 1,000 radio-frequency parts on each Wideband Global SATCOM (WGS) satellite currently in production and multiple small‑satellite product lines with fully 3D‑printed structures.
The new array approach is designed to scale from small satellites to larger platforms, including Boeing 702‑class spacecraft, targeting market availability for 2026.
By printing the panel's structure and built‑in features, Boeing can assemble the array in parallel with cell production. Robot‑assisted assembly and automated inspection at Spectrolab further reduce handoffs, improving speed and consistency.
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Contact
Zeyad Maasarani
Boeing Communications
+1-562-400-5533
zeyad.maasarani@boeing.com
Boeing Media Relations
media@boeing.com
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