Boeing streamlines solar array construction by as much as 50% through the use of 3D printing technology.
In the ever-evolving world of space exploration, several significant advancements have been made recently. Here's a snapshot of some of the most noteworthy developments:
Boeing Invests in 3D Printed Solar Arrays
Boeing, a global leader in the space industry, has invested over half a million pounds in additional machinery to extend its engineering capabilities. The company is focusing on the development of a 3D printed solar array substrate, which is expected to reduce weight and manufacturing costs. This innovation could potentially cut composite build times by up to six months, making space missions more efficient and cost-effective.
Boeing's 3D Printed Solar Array Approach
The new array approach, designed to scale from small satellites to larger platforms, including Boeing 702-class spacecraft, targets market availability for 2026. Boeing's approach enables a parallel build of the complete array, pairing a printed, rigid substrate with flight-proven modular solar technologies. This method delivers up to a 50% improvement in production speed compared to current cycle times.
Flight-Representative Hardware Testing
Flight-representative hardware has completed engineering testing and is progressing through Boeing's standard qualification path. The first 3D printed solar arrays will fly Spectrolab solar cells aboard small satellites built by Millennium Space Systems.
Orbex's Successful Simulation and Launch
Orbex, another key player in the space industry, has successfully completed its first full simulation of the Prime vehicle launch. Separately, the X-37B Orbital Test Vehicle, launched aboard a SpaceX Falcon 9 rocket, commenced its eighth mission.
Lockheed Martin's F-16 Upgrade
Lockheed Martin will upgrade the Republic of Korea Air Force's F-16 Block 52 flight simulators to mirror the advanced capabilities of its modernised F-16 Viper (F-16V) aircraft. By printing features such as harness paths and attachment points directly into each panel, the design replaces dozens of separate parts, streamlining the manufacturing process.
NASA's Preparations for Artemis II and III
NASA has begun assembling the Space Launch System (SLS) rocket for the Artemis III lunar mission, following the preparations for the Artemis II launch. These missions are part of NASA's commitment to return humans to the Moon and prepare for future missions to Mars.
Boeing's Role in Robot-Assisted Assembly
Boeing can assemble the array in parallel with cell production using robot-assisted assembly and automated inspection. This technology could potentially revolutionise the way spacecraft are assembled, increasing efficiency and reducing human error.
3D Printing Across the Industry
Across the Boeing portfolio, the company has incorporated more than 150,000 3D printed parts, yielding significant schedule, cost, and performance benefits. Similarly, NCC has adopted Dassault Systèmes' 3DEXPERIENCE platform on the cloud and extended its use to other innovation centres.
These advancements highlight the ongoing innovation and progress in the space industry, as companies continue to push the boundaries of what is possible in space exploration and manufacturing.
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