Initial steps towards a robotic solution for the manufacturing and assembly of thin-film space solar arrays

Print-assisted photovoltaic panel assembly (PAPPA), a novel printed electronic process presented herein, uses additive manufacturing to print flexible paneling components around commercial off-the-shelf thin-film solar cells. This builds a fully functional, flexible solar panel, suitable for space environments, via an automated process. Currently, thin-film space solar panels are manufactured via the compilation of piece parts by hand. In contrast PAPPA automates the labor-intensive paneling process. The advantages are twofold: (i) near-term: solar panel cost reduction alongside the enablement of very large-scale production and (ii) long-term: builds towards a capability for in-space solar panel manufacturing. Herein, details of the process, proof-of-concept functional testing, and implications for further development and application are presented.