Space & Satellites
Boeing Advances Space Manufacturing with 3D-Printed Solar Arrays
Boeing’s 3D-printed solar array substrates cut production time by 50%, boosting satellite manufacturing efficiency and scalability.
Boeing’s recent unveiling of its 3D-printed solar array substrate technology marks a significant milestone in the evolution of space hardware manufacturing. Announced on September 10, 2025, this innovation promises to cut production timelines by up to 50% and compress composite build times by as much as six months for typical solar array wing programs. The technology, a product of collaboration between Boeing’s additive manufacturing division, Spectrolab’s solar expertise, and Millennium Space Systems’ production capabilities, is poised to reshape the competitive landscape of the rapidly growing space sector.
With engineering testing completed and qualification underway, Boeing targets market availability for 2026. The technology’s initial focus is on small satellites, with scalability for larger platforms, including the Boeing 702-class spacecraft. This move comes as the global aerospace solar array market is projected to grow from $8 billion to $12 billion by 2030, driven by the surge in demand for satellite constellations and advances in solar cell efficiency. More than a step-change in manufacturing, Boeing’s approach signals a fundamental shift towards digitized, automated, and serial production in space hardware.
The journey of solar array technology in space has been marked by incremental yet impactful innovation, with Boeing’s subsidiary Spectrolab at the forefront. Spectrolab has a storied history of setting solar cell efficiency records, achieving a 38.8% energy conversion efficiency in 2013, a feat verified by the U.S. Department of Energy’s National Renewable Energy Laboratory. Earlier, in 2008, the company surpassed the 40% barrier in lab conditions, cementing its reputation as a leader in high-efficiency photovoltaics for space applications.
Traditionally, solar array manufacturing has been a laborious process, involving numerous discrete components, specialized tooling, and time-consuming assembly steps. These complexities not only extended production timelines but also introduced supply chain vulnerabilities and increased costs. For space missions, where reliability and precision are paramount, these legacy processes became limiting factors as satellite deployment schedules accelerated.
Boeing’s foray into additive manufacturing began in the early 2000s, with over 150,000 3D-printed parts now integrated across its aerospace portfolio. This experience includes more than 1,000 radio-frequency parts per Wideband Global SATCOM satellite and fully 3D-printed structures in small-satellite product lines. Such a foundation set the stage for the leap to 3D-printed solar array substrates, enabling Boeing to transfer lessons learned from aviation to the unique demands of the space sector.
Spectrolab’s solar panels currently power approximately 60% of all satellites in orbit, including the International Space Station. However, as the commercial space industry pivots toward mass satellite constellations, the traditional build-to-order approach has become a bottleneck. The need for speed, scalability, and cost-efficiency has never been greater, prompting a re-examination of manufacturing paradigms.
NASA’s own research, such as the Photovoltaic Array Production Automation (PAPA) project, underscores the industry-wide recognition of automation’s potential. PAPA estimates suggest cost savings of $300–$400 per watt for large-scale extraterrestrial solar arrays, with overall program savings potentially reaching hundreds of millions of dollars.
Boeing’s 3D-printed substrate initiative is thus both a response to competitive pressures and a proactive step to maintain leadership in a market where production throughput and flexibility are increasingly critical.
“Spectrolab’s solar cells and panels have powered the majority of satellites in orbit, but the future of space will demand new levels of manufacturing agility and integration.”
Boeing’s additive manufacturing journey began with the qualification of 3D-printed metal parts for military aircraft in 2003. Since then, the company has systematically expanded its capabilities, now boasting more than 50,000 3D-printed components on commercial and defense aircraft. This deep experience with material qualification, process control, and quality assurance has been instrumental in adapting additive techniques for space-grade applications.
The transition from prototype to production-scale 3D printing required rigorous validation. Boeing’s approach involves parallel build strategies, robot-assisted assembly, and automated inspection, significantly reducing manual labor and the risk of human error. These advances have paved the way for the integration of complex, multi-functional parts in a single manufacturing step.
The result is a manufacturing process that is not only faster but also more consistent and adaptable, capable of meeting the stringent requirements of space missions while offering cost and schedule advantages.
At the heart of Boeing’s new approach is the 3D-printed solar array substrate, a component that integrates harness paths, attachment points, and other features directly into the panel. This replaces dozens of separate parts and eliminates the need for specialized tooling and delicate bonding steps. The process leverages qualified additive manufacturing materials and is compatible with Spectrolab’s proven solar technologies.
The innovation enables a parallel build approach: while the rigid substrate is printed, modular solar cells are produced and tested, allowing for simultaneous assembly and integration. This not only compresses timelines but also facilitates rapid scaling to meet fluctuating demand, a key advantage as the satellite market pivots to large-scale constellations.
Automation is a cornerstone of the new process. Robot-assisted assembly and automated inspection at Spectrolab further reduce handoffs and manual interventions, improving both speed and quality. The design freedom afforded by 3D printing allows for optimized material distribution, reduced weight, and enhanced structural performance, all critical factors for space hardware.
“By integrating multiple functions into a single printed component, we’re able to cut production time in half and respond more rapidly to customer needs.”
Boeing’s strategy is to initially implement the 3D-printed solar array technology on small satellites developed by Millennium Space Systems, which Boeing acquired in 2018. Millennium specializes in high-performance satellites for a range of missions, providing an ideal testbed for the new manufacturing approach.
This phased deployment allows Boeing to validate the technology in operational environments, gather performance data, and refine processes before scaling to larger, more complex platforms like the Boeing 702-class spacecraft. The 702 family covers a broad spectrum of satellite applications, from 3–8 kilowatts (702SP) to over 12 kilowatts (702HP), ensuring wide applicability for the new technology.
The modularity and scalability of the 3D-printed substrate approach position Boeing to address diverse customer requirements and mission profiles, from low Earth orbit smallsats to high-power geostationary platforms.
The global space economy is on an upward trajectory, expected to surpass $1 trillion by 2040. Satellite deployments are accelerating, with an estimated 24,000 satellites projected to launch between 2023 and 2031. The aerospace solar array market itself is forecasted to grow from $8 billion in 2023 to $12 billion by 2030.
The satellite solar panel segment is expanding even more rapidly, with market size expected to rise from $2.5 billion in 2024 to $7.8 billion by 2033. This growth is fueled by the proliferation of small satellite constellations, which require efficient, lightweight, and rapidly manufacturable solar arrays.
Boeing’s 3D-printed technology directly addresses key industry pain points: long production cycles, high costs, and supply chain complexity. By consolidating parts and automating assembly, Boeing reduces labor, inventory, and procurement expenses. The 50% reduction in production time translates to lower working capital requirements and faster time-to-market for satellite operators.
“The new approach slashes both direct and indirect costs, positioning Boeing to compete for high-volume constellation contracts where speed and price are paramount.”
The aerospace solar array sector is dominated by a handful of major players, Airbus, Lockheed Martin, Northrop Grumman, and Boeing itself. However, the shift toward commercial constellations and rapid deployment is opening the door for disruptive manufacturing approaches.
Boeing’s integration of additive manufacturing with solar cell expertise and smallsat production creates a differentiated offering that is difficult for competitors to replicate quickly. The company’s vertical integration, from cell manufacturing (Spectrolab) to final assembly (Millennium Space Systems), allows for tighter quality control and supply chain resilience.
Internationally, China leads terrestrial solar panel manufacturing, holding 80% of global capacity, but space-grade arrays require specialized processes and materials. Boeing’s experience and certification processes provide a competitive edge as global demand for space hardware grows.
Boeing’s 3D-printed solar array substrate is more than a technological upgrade, it’s a harbinger of broader industry transformation. The convergence of additive manufacturing, robotics, and automation is setting the stage for serial production in aerospace, a shift from the bespoke, low-volume practices of the past.
The technology’s digital nature opens the door for integration with artificial intelligence, advanced materials, and predictive maintenance systems. As the process matures, further gains in efficiency, quality, and scalability are likely, enabling manufacturers to meet the demands of mega-constellations and deep space missions.
The modular, distributed nature of 3D printing also facilitates international expansion and localized production, reducing dependency on complex global supply chains. This adaptability is especially valuable as space-faring nations seek to build indigenous capabilities and reduce import reliance.
“Additive manufacturing is enabling a new era of agility and scalability in space hardware, Boeing’s leadership in this domain sets a benchmark for the industry.”
Boeing’s 3D-printed solar array substrate technology signals a new chapter in space manufacturing, offering dramatic reductions in production time and cost while enhancing scalability and quality. The company’s integration of expertise across additive manufacturing, high-efficiency solar cells, and satellite production positions it at the forefront of the next wave of space industry innovation.
As the global space economy accelerates and satellite constellations become the norm, Boeing’s manufacturing advances are likely to set new standards for efficiency and competitiveness. The broader implications extend beyond Boeing, encouraging the entire sector to embrace digital, automated, and scalable production methods that will define the future of space exploration and commercialization.
What is Boeing’s 3D-printed solar array substrate technology? How much does the new technology reduce production time? When will the technology be available for commercial use? What are the main benefits of 3D printing in aerospace manufacturing? Who are Boeing’s main collaborators in this project? Sources:
Boeing Revolutionizes Space Manufacturing with 3D-Printed Solar Array Technology
Background and Historical Context of Space Solar Array Manufacturing
Spectrolab’s Legacy and the Need for Change
Boeing’s Additive Manufacturing Experience
Technology Overview and Manufacturing Innovation
Initial Deployment and Scalability
Market Context and Economic Impact
Competitive Landscape
Future Outlook and Industry Transformation
Conclusion
FAQ
It is an integrated manufacturing approach that uses 3D printing to create solar array substrates with built-in features, reducing part count, assembly time, and production costs for space solar panels.
Boeing reports up to a 50% reduction in production time, compressing composite build times by as much as six months on typical solar array wing programs.
Boeing targets market availability in 2026, with initial deployment on small satellites and plans to scale to larger spacecraft.
3D printing enables design flexibility, part consolidation, reduced tooling and inventory costs, faster prototyping, and improved scalability for high-volume production.
The initiative involves Boeing’s additive manufacturing division, Spectrolab (for solar technology), and Millennium Space Systems (for satellite production).
Boeing Press Release
Photo Credit: Boeing
Space & Satellites
FAA Issues Safety Alert on Space Launch Debris Risks After Starship Incidents
FAA warns pilots of debris risks from commercial space launches after 2025 Starship incidents, urging enhanced flight planning near launch corridors.
This article summarizes reporting by the National Business Aviation Association (NBAA) and official FAA safety alerts.
The Federal Aviation Administration (FAA) has issued a formal warning to air carriers and pilots regarding the risks posed by commercial space launch failures. Released on January 8, 2026, Safety Alert for Operators (SAFO) 26001, titled “Airspace Management Considerations for Space Launch Activities,” advises the aviation industry to prepare for “catastrophic failures” that could scatter debris into navigable airspace.
This regulatory move follows a year of record-breaking launch activity and specific high-profile incidents in 2025 involving SpaceX’s Starship program. According to reporting by the National Business Aviation Association (NBAA) and other industry sources, the alert highlights the growing complexity of sharing the skies with experimental rocketry.
The alert comes at a critical time for the National Airspace System (NAS), which has faced strain from a federal government shutdown in late 2025 and early 2026. These staffing challenges previously forced the FAA to restrict commercial launches to nighttime hours to minimize conflicts with passenger traffic.
The core of the new safety alert focuses on the distinction between planned hazard zones and emergency contingency zones. While pilots are accustomed to Aircraft Hazard Areas (AHAs), pre-planned no-fly zones active during every launch, the FAA is now emphasizing the critical nature of Debris Response Areas (DRAs).
A DRA is an airspace volume that is only activated immediately following a launch mishap, such as an explosion or loss of control. The FAA warns that these areas are not theoretical; historical data indicates that debris often falls outside the immediate hazard area during catastrophic failures.
In the text of the alert, the FAA advises:
“Past events have shown that when a mishap does occur, debris has fallen within or near the DRA.”
Federal Aviation Administration, SAFO 26001
To mitigate these risks, the FAA and NBAA are urging operators to adopt conservative flight planning measures when operating near launch corridors, such as the Florida coast, the Gulf of Mexico, and the California coast. Key recommendations include:
The issuance of SAFO 26001 appears to be a direct response to safety data gathered throughout 2025. According to industry reports, a specific incident involving SpaceX Starship Flight 7 on January 16, 2025, served as a primary trigger for heightened scrutiny.
During that test flight, the vehicle experienced a “rapid unscheduled disassembly” over the Caribbean. Debris from the upper stage reportedly fell near areas active with commercial air traffic. Subsequent reporting by The Wall Street Journal in December 2025 revealed that internal FAA documents characterized the event as creating a “potential extreme safety risk.”
Subsequent mishaps involving Starship Flight 8 in March 2025 and Flight 9 in May 2025 further underscored the unpredictability of debris fields generated by massive experimental vehicles. With commercial launches reaching a record 148 in 2024 and projected to exceed 160 in 2025, the statistical probability of airspace conflict has risen significantly.
The aviation industry has reacted with caution to the new guidelines. The NBAA has advised its members to take the alert seriously, noting that business jet operators must be prepared for “last-minute” airspace closures that differ from standard planned restrictions.
Dean Snell, NBAA’s senior manager of Air Traffic Services, emphasized the operational difficulty of DRAs compared to standard hazard areas. While AHAs are predictable, DRAs require instant reaction from air traffic control and pilots.
Pilot unions, including the Airline Pilots Association (ALPA), have also expressed concern. Pilots operating over the Gulf of Mexico and the Atlantic are now urged to treat launch windows with a level of caution similar to that used for severe weather systems.
The timing of the alert coincides with broader systemic issues. A federal government shutdown spanning late 2025 into January 2026 resulted in staffing shortages among air traffic controllers and FAA safety personnel. To manage safety with reduced staff, the FAA issued an emergency order in November 2025 restricting commercial space launches to nighttime hours, typically 10:00 PM to 6:00 AM local time.
The introduction of Debris Response Areas as a standard consideration for flight planning represents a significant shift in the economics of air travel near spaceports. The requirement for “just-in-case” fuel reserves adds a tangible cost layer for airlines already operating on tight margins. Furthermore, the normalization of “catastrophic failure” planning suggests that regulators no longer view rocket explosions as rare anomalies, but as routine hazards inherent to the rapid iteration cycles of modern commercial spaceflight. We expect this to lead to increasingly rigid flight corridors around the Gulf of Mexico, potentially reducing airspace capacity permanently during launch windows. Sources:
FAA Issues Urgent Safety Alert on Space Launch Debris Risks Following Starship Incidents
Understanding SAFO 26001: Debris Response Areas
Operational Recommendations for Pilots
The Catalyst: 2025 Starship Incidents
Industry Reaction and Government Strain
Impact of the Government Shutdown
AirPro News Analysis
NBAA: FAA Safety Alert Focuses on Space Launches
FAA Safety Alert for Operators (SAFO 26001)
Photo Credit: NBAA
Space & Satellites
China Experiences Rare Dual Rocket Launch Failures in One Day
On January 17, 2026, China’s Long March 3B and Galactic Energy’s Ceres-2 rockets both failed, impacting classified and commercial satellites.
This article summarizes reporting by the South China Morning Post and official statements from CASC and Galactic Energy. The original SCMP report may be paywalled; this article summarizes publicly available elements and public remarks.
On Saturday, January 17, 2026, China’s rapidly expanding space sector suffered a significant and rare setback, experiencing two separate launch failures within a span of approximately 12 hours. The incidents, which involved both a veteran state-owned vehicle and a debuting commercial rocket, have been dubbed “Black Saturday” on Chinese social media platforms.
According to reporting by the South China Morning Post (SCMP), these twin failures are viewed by observers as symptoms of the industry’s growing pains as it pushes for an unprecedented launch cadence. The failures halted a long streak of successes for the state sector and marked a stumbling block for one of the country’s leading private space firms.
The two failures occurred at different launch sites and involved vastly different hardware, and risk, currently present in the Chinese aerospace sector.
The first incident occurred at 12:55 AM Beijing Time at the Xichang Satellite Launch Center. The Long March 3B (CZ-3B), operated by the state-owned China Aerospace Science and Technology Corporation (CASC), failed to deliver its payload, the classified Shijian-32 satellite, into orbit.
Official statements from CASC indicate that the rocket performed normally during its first two stages. However, a malfunction in the third-stage booster prevented the satellite from reaching its intended orbit. This failure is particularly notable because the Long March 3B is considered a “workhorse” of China’s orbital fleet. Before this event, the vehicle had maintained a success streak lasting over five years, with its last recorded failure occurring in April 2020.
Less than 12 hours later, at 12:08 PM Beijing Time, the private commercial sector suffered its own loss. The Ceres-2, a new solid-propellant rocket developed by Beijing-based Galactic Energy, failed during its maiden flight from the Jiuquan Satellite Launch Center.
Galactic Energy confirmed via a public statement that the rocket suffered an anomaly shortly after liftoff. The payload included six commercial satellites, notably the Lilac-3, a student-developed microsatellite from the Harbin Institute of Technology. The company issued an apology and stated that an investigation is currently underway. This failure contrasts sharply with the company’s previous success with the smaller Ceres-1 rocket. The timing of these failures has sparked discussion regarding the pressure placed on China’s space industry. According to the South China Morning Post, observers suggest these events are part of the sector’s growing pains.
China executed a record-breaking number of launches in 2025, and the 2026 schedule is reportedly even more aggressive, aiming to support major national projects such as the Chang’e 7 lunar mission. Experts cited in reports suggest that the systemic strain of maintaining such a high operational tempo may be impacting quality control processes, even for mature systems like the Long March 3B.
While launch failures are an inherent risk in spaceflight, the simultaneous failure of a legacy state rocket and a private commercial rocket on the same day is statistically anomalous. At AirPro News, we note that the failure of the Long March 3B is likely the more concerning of the two for Chinese officials. The Ceres-2 failure can be attributed to the inherent risks of a maiden flight and the “fail fast” iteration model adopted by private firms. However, the Long March 3B is a mature system; its failure suggests that supply chain or quality assurance fatigue may be setting in as the state demands higher launch frequencies to meet 2026 goals.
What was the “Black Saturday” event? What satellites were lost? Does this affect China’s 2026 space goals?
China’s Space Program Hits “Black Saturday” with Rare Double Failure
The Incidents: A Veteran and a Debutant
Failure 1: Long March 3B Stumbles
Failure 2: Ceres-2 Maiden Flight Crash
Industry Context: The Cost of Speed?
AirPro News Analysis
Frequently Asked Questions
“Black Saturday” refers to January 17, 2026, when China suffered two rocket launch failures in a single day involving the Long March 3B and the Ceres-2.
The state launch lost the Shijian-32, a classified experimental satellite. The commercial launch lost six satellites, including the Lilac-3, a student-developed research satellite.
While investigations are underway, the Long March 3B is a critical vehicle. A lengthy grounding could impact the schedule for other missions, though the Chinese space program has historically shown resilience and the ability to return to flight quickly.
Sources
Photo Credit: Xinhua
Commercial Space
Singapore Airshow 2026 Launches Space Summit and New Features
Singapore Airshow 2026 expands with inaugural Space Summit, sustainability focus, and advanced defense technologies from Feb 3-8.
The Singapore Airshow will return to the Changi Exhibition Centre from February 3 to 8, 2026, marking its 10th edition with a significant expansion into the commercial space sector. According to an official press release from the organizers, Experia Events, the biennial event will celebrate its 20th anniversary under the theme “New Frontiers in Aviation and Space.”
As one of the most influential aerospace and defense exhibitions in the Asia-Pacific region, the 2026 edition aims to bring together over 1,000 participating companies from more than 50 countries. The event will feature a strategic evolution from traditional aviation to include the rapidly growing space economy, alongside a continued focus on sustainability and advanced defense technologies.
For the first time, the Airshow will host the Space Summit 2026, a dedicated event running from February 2 to 3 at the Sands Expo and Convention Centre. This summit is designed to position Singapore as a central hub for space dialogue in the region, covering topics such as space infrastructure, investment, and the “in-space economy.”
Organizers highlighted the economic potential of this sector, citing McKinsey projections that the global space economy could reach $1.8 trillion by 2035. The summit is organized in partnership with the Office for Space Technology & Industry (OSTIn) and will feature leaders from global space agencies and commercial enterprises.
“Space technologies are becoming increasingly integral to our economy… The Space Summit@Singapore Airshow in 2026 provides a timely platform to spotlight Singapore’s capabilities in innovation and foster global partnerships across the space value chain.”
, Mr. Jonathan Hung, Executive Director, Office for Space Technology & Industry (OSTIn)
While expanding into space, the Airshow maintains its core focus on decarbonization and defense. The 2026 edition will spotlight Sustainable Aviation Fuel (SAF) and net-zero initiatives, with Neste returning as the Sustainable Aviation Partner to address supply chain adoption.
In the defense sector, the exhibition will showcase “next-generation” technologies, specifically highlighting companies specializing in artificial intelligence and autonomy, such as Helsing, Quantum, and Shield AI. The event will also feature expanded zones for digital aviation and Advanced Air Mobility (AAM), reflecting the region’s growing interest in electric vertical take-off and landing (eVTOL) aircraft.
The decision to formally integrate a Space Summit into the Singapore Airshow reflects a broader industry trend where the lines between traditional aerospace and the commercial space sector are blurring. By anchoring the event with a dedicated space summit, Singapore is likely attempting to replicate its success as an aviation hub in the nascent “New Space” market. This move allows the Airshow to remain relevant as defense budgets increasingly allocate funds to satellite infrastructure and space-based assets, ensuring the event appeals to a wider array of investors and policymakers beyond conventional aircraft manufacturers. The 2026 event marks two decades since the Airshow’s inception in 2008. The organizers report that the previous edition in 2024 signaled a full recovery from the pandemic, attracting approximately 60,000 trade attendees and generating a record S$391 million in economic impact. Experia Events expects the 10th edition to match or exceed these figures, driven by the Asia-Pacific region’s demand for new aircraft.
“Reaching our 10th edition is a significant milestone for Singapore Airshow. Over the past two decades, the Airshow has evolved alongside the industry… In 2026, we are proud to expand our horizons further with new features and partnerships that reflect the industry’s transformation.”
, Mr. Leck Chet Lam, Managing Director of Experia Events
Singapore Airshow 2026 to Launch “New Frontiers” with Inaugural Space Summit
Expanding into the Space Economy
Sustainability and Advanced Defense
AirPro News Analysis
A Milestone Year for the Industry
Frequently Asked Questions
Sources
Photo Credit: Secretary of the Air Force International Affairs
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