High-Volume Production of Lightweight, Multi-Junction Solar Cells Using 6-inch GaAs

MicroLink Devices has been developing high-efficiency, lightweight and flexible epitaxial lift-off (ELO) solar cells over the past decade. This technology is now entering a critical commercialization phase with the potential for significant growth. ELO solar cells are an enabling technology for solar-powered, high-altitude, long-endurance unmanned aerial vehicles (HALE UAVs), which can fly continuously for weeks to months at a time above 60,000 feet. HALE UAVs can provide similar functionality to satellites when equipped with cameras, radars and telecommunication equipment. Emerging markets in HALE UAVs as well as constellation satellites may require MWs/year of solar cells over the next decade. A successful production ramp-up of ELO solar cells will provide a high-volume manufacturing base of ELO solar cells essential for future NASA SEP missions. Airbus has been secured as a customer for MicroLink solar cells; investment is needed to transition to a high-volume, low-cost manufacturing process. The proposed CCRPP program has three primary objectives. We will develop advanced robotic automation equipment and processes to address a critical need for reducing labor in the assembly of ELO solar cell arrays. The second task is to implement a novel new cell geometry that improves wafer utilization by 30%. Finally, we will develop and qualify a radiation-hard inverted metamorphic multi-junction (IMM ELO) solar cell structure. The two-year, $2M program will reduce manufacturing costs by more than 30% and enable scale-up from current production volumes of tens of kW/year to a platform capable of supporting greater than 1MW/year.

NASA has funded the development of MicroLink’s ELO solar cell technology for its potential use in future solar electric propulsion (SEP) for planetary exploration missions. SEP uses ion thrusters powered by very large solar arrays that will require a new technology of solar cells that is light-weight, high-efficiency, radiation-hard, and significantly lower cost than existing multi-junction solar cells used for space arrays. NASA is also exploring potential HALE UAV applications, for which MicroLink’s IMM ELO solar cells would be well suited.

Low-cost solar cells for low-earth orbit (LEO) constellation satellites. HALE UAVs for intelligence, surveillance and reconnaissance (ISR) as well as telecommunications relays. Solar sheets for generation of electricity for off-grid applications, e.g., military forward operating bases and power on the move, civilian outdoors and camping, and supplementary power for mobile devices such as phones.

This is a mature technology (TRL 9) — the realistic path in is usually NASA's Technology Transfer Program: licensing an existing NASA patent, or a Space Act Agreement to use NASA facilities/expertise directly. NASA also runs a startup licensing program with no upfront fee for companies formed to commercialize a specific NASA technology.

None of these are guaranteed paths for this specific project — TechPort itself doesn't have an "apply" button. Reaching out to the contact(s) above with a specific question is usually the fastest way to find out what's actually open.