Automated High-Volume Manufacturing of Modular Photovoltaic Panel Assemblies for Space Solar Arrays

Deployable Space Systems, Inc. (DSS) will focus the proposed SBIR program on the creation and development of an automated robotic manufacturing infrastructure designed to mass-produce DSS's Integrated Modular Blanket Assembly (IMBA) common photovoltaic Standard Power Modules (SPM's). The proposed development will implement automated manufacturing processes for CIC-ing, glassing, stringing, laydown, and acceptance testing of interconnected photovoltaic devices onto an ultra-lightweight IMBA/SPM modular flexible blanket assembly through simple and commercially available pick-and-place robotic manufacturing techniques / infrastructure. Automated manufacturing of IMBA/SPM photovoltaic panel assemblies will provide an industry paradigm shift for affordability / cost-savings when compared to current labor intensive manufacturing processes. Unlike the current industry approach which is only focused on increasing the device area that only minimally reduces panel assembly costs, the proposed automated manufacturing will attack the highest cost and most labor intensive components of manufacturing a panel assembly, namely; CICing, glassing, stringing, panel laydown, and acceptance testing. By incorporating automated manufacturing the proposed IMBA/SPM photovoltaic flexible blanket assembly promises to provide ultra-affordable high-performance and repeatable high-quality modules for future NASA Space Science and Exploration missions, and particularly for ultra-high-power SEP missions.

NASA space applications are comprised of practically all Exploration, Space Science, Earth Science, Planetary Surface, and other missions that require high-efficiency photovoltaic power production through affordable solar arrays. The technology is particularly suited for NASA's SEP missions and other missions that require game-changing performance in terms of extremely large deployed areas, affordability, ultra-lightweight, and compact stowage volume. The technology is also well suited for applications requiring scalability/modularity, operability within high radiation environments, high voltage operation, and LILT/HIHT operation. The proposed technology is estimated to ultimately reduce standard photovoltaic panel assembly costs by an astounding 50% for space applications.

Non-NASA space applications are comprised of practically all missions that require high-efficiency photovoltaic power production through affordable solar arrays. The technology is particularly suited for SEP missions that require game-changing performance in terms of large deployed areas, affordability, ultra-lightweight, and compact stowage volume. Applicable non-NASA space missions include: LEO surveillance, reconnaissance, communications and other critical payload/equipment satellites, LEO commercial mapping and critical payload/equipment satellites, MEO satellites & space-tugs, GEO commercial communications and critical payload/equipment satellites, and GEO communications and payload/equipment satellites. The proposed technology also has tremendous dual-use non-space commercial private-sector applicability including fixed-ground and deployable/retractable mobile-ground based systems whereby such automation allows commercial affordability. The proposed technology is estimated to ultimately reduce standard photovoltaic panel assembly costs by an astounding 50% for space applications.

This is early/mid-stage (TRL 4) — the most realistic path in is NASA SBIR/STTR, which funds small businesses and research institutions to develop technology aligned with NASA's needs (equity-free, phased funding). Check whether a current SBIR/STTR solicitation topic overlaps with this project's technology area, or contact the project directly (above) to ask.

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