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
Sodern Opens First US Facility in Colorado for Star Tracker Production
Sodern launches its first US industrial subsidiary in Colorado, producing Auriga™ star trackers and expanding in the US aerospace market.
This article is based on an official press release from Sodern.
Sodern, a prominent French manufacturer of space equipment and a subsidiary of ArianeGroup, has officially inaugurated its first United States industrial subsidiary, Sodern America. Located in Englewood, Colorado, the new facility marks a significant strategic expansion for the European aerospace giant, representing ArianeGroup’s first industrial installation on American soil.
According to the company’s announcement, the opening of Sodern America is designed to bring the manufacturer closer to its U.S. client base and navigate domestic regulatory requirements. The move positions Sodern to compete directly with established American firms in the defense and commercial space sectors by establishing a local supply chain and production capability.
The new subsidiary is situated in the Denver metropolitan area, a region widely recognized as a major hub for the U.S. aerospace industry. The facility spans approximately 14,000 square feet (1,300 square meters) and is equipped to handle manufacturing, testing, and commercial support.
In its official statement, Sodern outlined the specific operational capabilities of the Englewood site:
By establishing this physical presence, Sodern aims to address the “dynamic and demanding” nature of the U.S. market, ensuring that critical components are available with shorter supply-chains than those requiring import from Europe.
To lead the new subsidiary, Sodern has appointed Tiphaine Louradour as the CEO of Sodern America. Louradour brings over 25 years of experience in the space industry, having held significant leadership roles at major U.S. aerospace organizations.
According to biographical details released in conjunction with the announcement, Louradour’s background includes serving as CEO of Spaceflight Inc., President of International Launch Services (ILS), and President of Global Commercial Sales at United Launch Alliance (ULA). Her appointment signals Sodern’s intent to leverage deep ties within the U.S. space industrial base to secure new contracts.
A primary driver for this expansion, as noted in the company’s strategic rationale, is compliance with U.S. regulatory frameworks. Foreign entities often face barriers when bidding for U.S. government defense and civil space contracts due to strict domestic content requirements, often referred to as “Buy American” mandates. By manufacturing the Auriga™ star tracker and conducting testing in Colorado, Sodern America intends to qualify for sensitive programs that are typically restricted to U.S. entities. This local status allows the company to bypass previous regulatory hurdles and compete on equal footing with domestic manufacturers.
The entry of Sodern America into the Colorado aerospace cluster places it in direct proximity to some of its fiercest competitors. The Denver area is home to Blue Canyon Technologies (a subsidiary of RTX), which is a market leader in small satellite components and star trackers. Additionally, Ball Aerospace (now part of BAE Systems Space & Mission Systems) and Honeywell Aerospace maintain significant operations in the region.
Sodern is already a supplier for major U.S. stakeholders, including NASA, providing instruments for the InSight Mars mission and the Europa Clipper, and the OneWeb constellation. However, establishing a manufacturing foothold suggests a shift from being an exporter to becoming an embedded part of the U.S. supply chain. This move is likely to intensify competition in the optical sensors market, particularly as satellite constellations continue to scale.
What is Sodern America? Where is the new facility located? What will be manufactured at the new site? Who is the CEO of Sodern America? Why did Sodern open a U.S. factory?
Facility Capabilities and Strategic Location
Leadership and Market Objectives
Navigating “Buy American” Regulations
AirPro News Analysis: The Competitive Landscape
Frequently Asked Questions
Sodern America is the new U.S. subsidiary of the French space equipment manufacturer Sodern. It is the company’s first industrial facility in the United States.
The facility is located in Englewood, Colorado, within the Denver metropolitan area.
The site will feature a production line for Auriga™ star trackers and testing facilities for Hydra™ star trackers.
Tiphaine Louradour, a veteran aerospace executive with previous leadership roles at Spaceflight Inc. and ULA, has been appointed as CEO.
The expansion aims to bypass “Buy American” regulatory hurdles, shorten supply chains for U.S. clients, and allow the company to bid on U.S. government defense contracts.Sources
Photo Credit: Sodern
Space & Satellites
Isar Aerospace Opens Acceptance Test Facility at Esrange Space Center
Isar Aerospace launches a new test site at Esrange, Sweden, to support industrial-scale production of Spectrum rocket ahead of March 2026 flight.
This article is based on an official press release from Isar Aerospace.
Isar Aerospace has officially inaugurated a new acceptance test facility at the Esrange Space Center in Kiruna, Sweden. Announced on February 4, 2026, the opening marks a significant transition for the Munich-based launch provider as it shifts focus from prototype development to the industrial-scale production of its Spectrum launch vehicle.
The new site is purpose-built to verify the flight readiness of manufactured hardware, a critical step in ensuring high-cadence Launch operations. According to the company, the facility is designed to test over 30 Aquila engines per month, alongside fully integrated rocket stages. This infrastructure expansion comes just weeks before Isar Aerospace attempts its second Test-Flights, mission “Onward and Upward,” scheduled to First-Flight from Andøya Spaceport in Norway in March 2026.
Unlike development testing, which focuses on validating design concepts, acceptance testing is the final quality control step before hardware is shipped to the launch pad. Isar Aerospace stated in their press release that the new facility is specifically engineered to remove production bottlenecks. By securing dedicated infrastructure for acceptance testing, the company aims to ensure that every engine and stage coming off the assembly line is immediately qualified for flight.
The facility operates alongside Isar’s existing vertical test stand (VTS-2) at Esrange, which has been utilized for development testing since 2019. The addition of the new site allows for parallel operations: R&D can continue on the vertical stand while the new facility handles the volume required for serial production.
“Scaling reliable access to space requires not only advanced launch vehicle design but also the right infrastructure to support rapid development and production. With our second test facility at Esrange, we are unlocking new capabilities and accelerating our progress.”
, Daniel Metzler, CEO & Co-Founder, Isar Aerospace
The new infrastructure significantly increases the company’s throughput. Isar Aerospace reports that the site is equipped to handle the acceptance testing of more than 30 Aquila engines monthly. Furthermore, the site supports integrated stage testing, allowing engineers to verify the entire rocket stage as a cohesive unit before it leaves Sweden.
The opening of this facility highlights the intensifying race among European launch Startups to provide sovereign access to space. Isar Aerospace is competing with peers such as Rocket Factory Augsburg (RFA) and Orbex to fill the gap in Europe’s launch market. By vertically integrating its testing capabilities, Isar Aerospace reduces reliance on shared facilities, potentially giving it an advantage in scheduling and launch cadence. Swedish Space Corporation (SSC), which operates Esrange, emphasized the importance of this Partnerships for the broader European ecosystem.
“This new facility strengthens Europe’s path toward scalable and reliable access to space… Together, we are building the infrastructure that will enable a new generation of launch services.”
, Mats Tyni, Director of Business Development, SSC
The distinction between “development” and “acceptance” testing is often overlooked, yet it is the primary hurdle for launch companies moving from a single successful flight to a commercial service. In our view, Isar Aerospace’s Investments in a high-volume acceptance facility signals confidence in their hardware design. It suggests the company believes the Aquila engine design is mature enough to freeze for mass production. If the upcoming March 2026 flight is successful, this infrastructure will be the key enabler that allows them to fulfill their backlog without the testing bottlenecks that have historically plagued the industry.
The facility inauguration serves as a prelude to Isar Aerospace’s next major milestone. The company confirmed that its second test flight, dubbed “Onward and Upward,” is targeted for a launch window in March 2026. This mission will utilize the Spectrum vehicle, a two-stage rocket designed to carry up to 1,000 kg to Low Earth Orbit (LEO).
The Spectrum vehicle relies on the Aquila engines tested at Esrange, which utilize Liquid Oxygen (LOX) and Propane. Following a flight termination during the first test launch in March 2025, the company has conducted extensive hot-fire tests to validate system corrections. The new acceptance facility will likely play a central role in qualifying engines for vehicles 3 through 7, which are currently planned for concurrent production.
Industrializing Launch Capabilities
Capacity and Specs
Strategic Context: The Race for European Sovereignty
AirPro News Analysis
Upcoming Mission: “Onward and Upward”
Sources
Photo Credit: Isar Aerospace
Space & Satellites
SpaceX Crew-12 Arrives in Florida for February ISS Launch
Crew-12 astronauts from NASA, ESA, and Roscosmos arrive at Kennedy Space Center ahead of their February 11 launch to the ISS aboard SpaceX Crew Dragon.
This article is based on an official press release from NASA and additional mission data from ESA and Roscosmos.
The four-member crew of the SpaceX Crew-12 mission arrived at the Kennedy Space Center (KSC) in Florida on Friday, February 6, 2026, marking the final operational milestone before their scheduled Launch to the International Space Station (ISS). Flying in from the Johnson Space Center in Houston, the international team of astronauts landed at the Launch and Landing Facility to commence final preparations and mandatory quarantine protocols.
According to NASA, the mission is targeted to lift off on Wednesday, February 11, 2026, at 6:01 a.m. EST. The crew will ride aboard the SpaceX Crew Dragon spacecraft named Freedom, propelled by a Falcon 9 rocket from Space Launch Complex 40 (SLC-40) at Cape Canaveral Space Force Station. This flight represents a continuation of the Commercial Crew Program’s efforts to maintain a continuous human presence in low-Earth orbit.
The arrival of Crew-12 is operationally critical for the ISS, which has recently functioned with a reduced staff due to schedule shifts and medical evaluations. The successful docking of Crew-12, targeted for approximately 10:30 a.m. EST on February 12, will restore the orbiting laboratory to its full complement of seven astronauts, stabilizing maintenance rosters and scientific output for Expeditions 74 and 75.
The Crew-12 mission brings together representatives from three major Space-Agencies: NASA, the European Space Agency (ESA), and Roscosmos. The mission duration is expected to last approximately nine months, during which the crew will conduct hundreds of scientific experiments and technology demonstrations.
In an official statement regarding the mission’s scope, NASA noted:
“Crew-12 will conduct scientific investigations and technology demonstrations to help prepare humans for future exploration missions to the Moon and Mars, as well as benefit people on Earth.”
Following the launch on February 11, the crew will execute a 28-hour rendezvous profile before docking with the ISS. Once aboard, they will overlap briefly with the departing crew before settling into a long-duration stay focused on deep space biology, material science, and Earth observation.
The manifest for Crew-12 features a blend of veteran leadership and rookie talent, including two American astronauts, one French astronaut, and one Russian cosmonaut. Leading the mission is veteran astronaut Jessica Meir. Meir previously served on Expedition 61/62 in 2019 and 2020, where she gained global recognition for participating in the first all-female spacewalk alongside Christina Koch. A dual American-Swedish citizen, Meir holds a Doctorate in Marine Biology from the Scripps Institution of Oceanography. Her scientific background includes extensive research on animal physiology in extreme environments, such as emperor penguins in Antarctica. As Mission Commander, she is responsible for all phases of flight, from launch to re-entry.
Seated alongside Meir is mission pilot Jack Hathaway, making his first trip to space. Selected as a NASA astronaut candidate in 2021, Hathaway brings extensive aviation experience as a Commander in the U.S. Navy. He is a distinguished graduate of the Empire Test Pilots’ School and has logged over 2,500 flight hours in more than 30 types of aircraft. His role on Crew-12 involves monitoring vehicle systems and performance during the dynamic phases of flight.
Representing the European Space Agency is Mission Specialist Sophie Adenot. A Lieutenant Colonel in the French Air and Space Force and a helicopter test pilot, Adenot was selected as an ESA astronaut in 2022. She becomes the second French woman to fly to space, following Claudie Haigneré’s mission in 1996. Adenot’s individual mission is designated “Epsilon.”
Commenting on the significance of her role, Adenot stated:
“With this Epsilon mission, France and Europe are contributing to a global endeavor. Space exploration connects science, economy, technology, education, and diplomacy.”
Rounding out the crew is Roscosmos cosmonaut Andrey Fedyaev. This flight marks his second journey to the ISS, having previously flown on the SpaceX Crew-6 mission from March to September 2023. Fedyaev’s inclusion in the crew is notable for making him the first Russian cosmonaut to fly twice on a SpaceX Dragon vehicle. He is tasked with monitoring launch and re-entry phases and managing cargo operations aboard the station.
Upon their arrival in Florida, the crew immediately entered the Neil A. Armstrong Operations and Checkout Building to begin the standard pre-flight quarantine. This health stabilization protocol, a legacy of the Apollo era, is designed to ensure that no viral or bacterial illnesses are transported to the closed environment of the ISS.
The composition of Crew-12 underwent a significant adjustment late in the training flow. In December 2025, Roscosmos cosmonaut Oleg Artemyev was removed from the manifest and replaced by Andrey Fedyaev. While Roscosmos officially cited a “transition to other work” as the reason for the swap, industry reports have suggested the change may have been influenced by internal Regulations. Fedyaev’s previous experience on the Crew-6 mission allowed him to step into the role with a compressed training timeline, ensuring the mission schedule remained on track.
The integration of Andrey Fedyaev into Crew-12 highlights the increasing maturity and interoperability of the Commercial Crew Program. In previous eras of spaceflight, a crew change less than three months before launch could have resulted in significant delays. However, the standardization of the SpaceX Crew Dragon platform allows veteran flyers like Fedyaev to retain currency and step into rotation with reduced lead time. Furthermore, the launch of Crew-12 is pivotal for ISS operations. The station has faced a period of flux regarding crew numbers, and the return to a seven-person staff is essential for clearing the backlog of maintenance tasks and maximizing the scientific return of the orbiting laboratory before the transition to commercial space stations begins later in the decade.
Sources:
Crew-12 Astronauts Touch Down in Florida Ahead of February 11 Launch
Mission Profile and Timeline
Meet the Crew-12 Astronauts
Commander Jessica Meir (NASA)
Pilot Jack Hathaway (NASA)
Mission Specialist Sophie Adenot (ESA)
Mission Specialist Andrey Fedyaev (Roscosmos)
Operational Context and Late Adjustments
Late Crew Change
AirPro News Analysis
Photo Credit: NASA
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