{"project":{"acronym":"","projectId":17750,"title":"Low Cost Automated Manufacture of PV Array Technology (P-NASA12-007-1)","primaryTaxonomyNodes":[{"taxonomyNodeId":10594,"taxonomyRootId":8816,"parentNodeId":10593,"level":3,"code":"TX03.1.1","title":"Photovoltaic","definition":"Photovoltaic electrical power generation converts photons into electrical power, including photovoltaic cells, cell integration, and mechanical and structural technologies for cell arrays.","exampleTechnologies":"25 – 150 kW-class solar arrays, reliably retractable solar arrays, reduced-cost photovoltaic blankets, extreme environment solar cells and panels","hasChildren":false,"hasInteriorContent":true}],"startTrl":4,"currentTrl":5,"endTrl":5,"benefits":"Low cost, lightweight, high power solar arrays with compact packaging and high voltage capability is an enabling technology for meeting the key NASA objective of implementing solar electric propulsion, which enables enhanced planetary, human exploration, and orbit transfer missions. With these missions projecting prime power growth to 25 - 300kW, the automated assembly of THINS arrays with today's space qualified triple junction cells meets these needs with improved specific power by a factor of >3X, an improved volumetric efficiency when stowed for launch by a factor of >8X, and a PVA cost reduction of >30% compared to today's solar arrays. The approach additionally prepares for the low cost integration of IMM solar cells as they become qualified. These improvements, together with demonstrated high operating voltage capability exceeding 300V, allow an affordable high power system up to hundreds of kW to be packaged into a single launch. The THINS Array also has the advantages of improved high voltage stability and electromagnetic cleanliness because of surface continuity available from encapsulation, with similar technology developed at Vanguard already transitioned through a NASA Phase III SBIR to the Magnetospheric MultiScale (MMS) mission.
The trend towards Solar Electric Propulsion to supplant chemical propulsion for orbit-raising and station-keeping, and the advent of \"all-electric\" spacecraft which use SEP for orbital transfer and stationkeeping, have driven the need for both higher power and higher voltage in commercial and DoD spacecraft. Commercial spacecraft have trended toward higher power to also provide more capability (e.g. more bandwidth or coverage) which translates directly to increased revenue for the spacecraft operator. Additional functionality for military spacecraft, including enhanced communication, reconnaissance, and on-orbit computational capabilities, as well as the maneuverability afforded by SEP also drive to higher power requirements. The implementation of a low mass, low volume, low cost array with improved cost and environmental robustness benefits all of these applications.","description":"Spacecraft for NASA, DoD and commercial missions need higher power than ever before, with lower mass, compact stowage, and lower cost. While high efficiency, space-qualified solar cells are in themselves costly, integrating them into a high performance Photovoltaic Assembly (PVA) using conventional glassing, interconnecting, stringing, tiling and laydown techniques can double their cost in $/Watt. The cost of solar power could be significantly reduced if the design of the Photovoltaic Assembly could be modified, modularized and standardized to be compatible with automated electronic assembly and terrestrial solar panel manufacturing methods. Additional benefits of such an approach include higher quality and consistency, improved qualification traceability, and robustness on thin flexible as well as rigid arrays. During the Phase I effort Vanguard successfully demonstrated automated pick-and-place, electrical interconnection, and adhesive dispensing adapted to our lightweight flexible Thin Integrated Solar (THINS) PVA. THINS uses multi-cell covers and advanced interconnection and encapsulation technology, which enables automated integration of traditional and advanced space qualified solar cells. Engineering economic analysis showed the potential for >30% PVA $/Watt cost reduction, while the encapsulation approach associated with THINS showed enhanced durability in space environments, even at high voltages and extreme thermal cycle environments. During the Phase II Program we will further enhance our automated sub-module manufacturing, and scale the approach to the module level. Automated assembly scale up will be performed while integrating into an existing deployable space structure platform, enhancing the TRL of a high performance high power application of automated cell integration scalable from tens to hundreds of kilowatts, and providing a credible commercialization path, all while reducing solar array costs by more than $150/W.","startYear":2014,"startMonth":4,"endYear":2016,"endMonth":10,"statusDescription":"Completed","principalInvestigators":[{"contactId":355624,"canUserEdit":false,"firstName":"Nicholas","lastName":"Walmsley","fullName":"Nicholas Walmsley","fullNameInverted":"Walmsley, Nicholas","primaryEmail":"nwalmsley@vst-inc.com","publicEmail":true,"nacontact":false}],"programDirectors":[{"contactId":206378,"canUserEdit":false,"firstName":"Jason","lastName":"Kessler","fullName":"Jason L Kessler","fullNameInverted":"Kessler, Jason L","middleInitial":"L","primaryEmail":"jason.l.kessler@nasa.gov","publicEmail":true,"nacontact":false}],"programExecutives":[{"contactId":215154,"canUserEdit":false,"firstName":"Jennifer","lastName":"Gustetic","fullName":"Jennifer L Gustetic","fullNameInverted":"Gustetic, Jennifer L","middleInitial":"L","primaryEmail":"jennifer.l.gustetic@nasa.gov","publicEmail":true,"nacontact":false}],"programManagers":[{"contactId":62051,"canUserEdit":false,"firstName":"Carlos","lastName":"Torrez","fullName":"Carlos Torrez","fullNameInverted":"Torrez, Carlos","primaryEmail":"carlos.torrez@nasa.gov","publicEmail":true,"nacontact":false}],"projectManagers":[{"contactId":322911,"canUserEdit":false,"firstName":"Matthew","lastName":"Myers","fullName":"Matthew G Myers","fullNameInverted":"Myers, Matthew G","middleInitial":"G","primaryEmail":"matthew.g.myers@nasa.gov","publicEmail":true,"nacontact":false},{"contactId":461333,"canUserEdit":false,"firstName":"Theresa","lastName":"Stanley","fullName":"Theresa M Stanley","fullNameInverted":"Stanley, Theresa M","middleInitial":"M","primaryEmail":"theresa.m.stanley@nasa.gov","publicEmail":true,"nacontact":false}],"website":"","libraryItems":[{"file":{"fileExtension":"pdf","fileId":302302,"fileName":"SBIR_2012_2_BC_H8.04-9949","fileSize":59000,"objectId":298845,"objectType":{"lkuCodeId":889,"code":"LIBRARY_ITEMS","description":"Library Items","lkuCodeTypeId":182,"lkuCodeType":{"codeType":"OBJECT_TYPE","description":"Object Type"}},"objectTypeId":889,"fileSizeString":"57.6 KB"},"files":[{"fileExtension":"pdf","fileId":302302,"fileName":"SBIR_2012_2_BC_H8.04-9949","fileSize":59000,"objectId":298845,"objectType":{"lkuCodeId":889,"code":"LIBRARY_ITEMS","description":"Library Items","lkuCodeTypeId":182,"lkuCodeType":{"codeType":"OBJECT_TYPE","description":"Object Type"}},"objectTypeId":889,"fileSizeString":"57.6 KB"}],"id":298845,"title":"Briefing Chart","libraryItemTypeId":1222,"projectId":17750,"primary":false,"publishedDateString":"","contentType":{"lkuCodeId":1222,"code":"DOCUMENT","description":"Document","lkuCodeTypeId":341,"lkuCodeType":{"codeType":"LIBRARY_ITEM_TYPE","description":"Library Item Type"}}},{"caption":"Low Cost Automated Manufacture of PV Array Technology (P-NASA12-007-1), Phase II","file":{"fileExtension":"jpg","fileId":302753,"fileName":"SBIR_2012_2_BC_H8.04-9949","fileSize":42445,"objectId":299298,"objectType":{"lkuCodeId":889,"code":"LIBRARY_ITEMS","description":"Library Items","lkuCodeTypeId":182,"lkuCodeType":{"codeType":"OBJECT_TYPE","description":"Object Type"}},"objectTypeId":889,"fileSizeString":"41.5 KB"},"files":[{"fileExtension":"jpg","fileId":302753,"fileName":"SBIR_2012_2_BC_H8.04-9949","fileSize":42445,"objectId":299298,"objectType":{"lkuCodeId":889,"code":"LIBRARY_ITEMS","description":"Library Items","lkuCodeTypeId":182,"lkuCodeType":{"codeType":"OBJECT_TYPE","description":"Object Type"}},"objectTypeId":889,"fileSizeString":"41.5 KB"}],"id":299298,"title":"Briefing Chart Image","description":"Low Cost Automated Manufacture of PV Array Technology (P-NASA12-007-1), Phase II","libraryItemTypeId":1095,"projectId":17750,"primary":true,"publishedDateString":"","contentType":{"lkuCodeId":1095,"code":"IMAGE","description":"Image","lkuCodeTypeId":341,"lkuCodeType":{"codeType":"LIBRARY_ITEM_TYPE","description":"Library Item Type"}}}],"transitions":[{"transitionId":64214,"projectId":17750,"partner":"Other","transitionDate":"2014-04-01","path":"Advanced From","relatedProjectId":16576,"relatedProject":{"acronym":"","projectId":16576,"title":"Low Cost Automated Manufacture of High Efficiency THINS ZTJ PV Blanket Technology (P-NASA12-007)","startTrl":3,"currentTrl":4,"endTrl":4,"benefits":"Low cost, lightweight, high power solar arrays with compact packaging is a key enabling technology for meeting a variety of NASA missions such as solar electric propulsion, outer planetary, or crew exploration missions. The automated THINS ZTJ approach is an ideal technology for meeting these needs, projecting a specific power improvement of greater than a factor of 3X, and an improved volumetric efficiency when rolled for launch by a factor of 4X compared to today's solar arrays. The approach additionally prepares for the low cost integration of IMM solar cells as they become economically feasible. Such improvements are needed to allow a high power system up to 300kW to be packaged into a single launch, avoiding expensive and risky on-orbit assembly. The THINS Array also has the advantages of improved electromagnetic shielding because of the continuity of coverglass materials and the ability to create a continuous grounded, shielded enclosure. Such a technology can be enabling for high performance electric and magnetic field instruments often used on NASA spacecraft, such as THEMIS, MMS, and Maven. (MMS solar arrays, in fact, have incorporated superstrate technology previously developed on a NASA Phase III SBIR from Vanguard).
Commercial spacecraft have trended towards higher power in recent years, with spacecraft prime power requirements growing from 5kW to over 20kW. Additional power provides additional functionality for military spacecraft, and additional revenue for commercial spacecraft, but is limited in practice to the 20kW level by the maximum achievable power that can be obtained with conventional rigid panel planar technology. The implementation of a low mass, low volume, low cost array has application to a broad spectrum of military and commercial users who currently are restricted by the mass, volume, and cost of conventional approaches.","description":"NASA needs lower cost solar arrays with high performance for a variety of missions. While high efficiency, space-qualified solar cells are in themselves costly, > $250/Watt, there is considerable additional cost associated with the parts and labor needed to integrate the Photovoltaic Assembly. The standard approach has evolved with only minor changes, sacrificing cost because of risk aversion. Integration cost can be as much as double the bare cell cost – i.e. >$500/watt. Dramatic cost savings can be realized through manufacturing engineering of more efficient automated assembly processes. If the design of the Photovoltaic Assembly could be modified to be compatible with conventional and automatable electronic assembly and terrestrial solar panel assembly approaches, there could be considerable cost savings. There are many additional benefits with automation which include higher quality and consistency. This can reduce failures, increase production throughput, speed turnaround, and improve overall reliability. Cost and quality improvements can be realized on both thin and rigid arrays, increasing current capabilities, and enabling future high power missions. The benefits of automation are enhanced by the need for high power generation in support of energy intensive space missions. A 300kW array at $500/W would cost $150M just for the solar cell integrated array panels. A $150/W cell integration cost reduction would translate into savings of $45M, before considering the immediate and substantial benefits in consistency, reliability, and schedule. The Phase I effort demonstrates feasibility of a low cost array using an automated and integrated manufacturing approach, performed on an automation friendly solar cell, verified with environmental testing, and is used to predict array cost for a high power mission. Meeting these technical objectives will demonstrate reduced cost and justify a Phase II SBIR program preparing for a flight experiment.","startYear":2013,"startMonth":5,"endYear":2013,"endMonth":11,"statusDescription":"Completed","website":"","program":{"acronym":"SBIR/STTR","active":true,"description":"
The NASA SBIR and STTR programs fund the research, development, and demonstration of innovative technologies that fulfill NASA needs as described in the annual Solicitations and have significant potential for successful commercialization. If you are a small business concern (SBC) with 500 or fewer employees or a non-profit RI such as a university or a research laboratory with ties to an SBC, then NASA encourages you to learn more about the SBIR and STTR programs as a potential source of seed funding for the development of your innovations.
The SBIR and STTR programs have 3 phases:
The SBIR and STTR Phase I contracts last for 6 months with a maximum funding of $125,000, and Phase II contracts last for 24 months with a maximum funding of $750,000 - $1.5 million.
Opportunity for Continued Technology Development Post-Phase II:
The NASA SBIR/STTR Program currently has in place two initiatives for supporting its small business partners past the basic Phase I and Phase II elements of the program that emphasize opportunities for commercialization. Specifically, the NASA SBIR/STTR Program has the Phase II Enhancement (Phase II-E) and Phase II eXpanded (Phase II-X) contract options.
Please review the links below to obtain more information on the SBIR/STTR programs.
Provides an overview of the SBIR and STTR programs as implemented by NASA
Provides access to the annual SBIR/STTR Solicitations containing detailed information on the program eligibility requirements, proposal instructions and research topics and subtopics
Schedule and links for the SBIR/STTR solicitations and selection announcements
Federal and non-Federal sources of assistance for small business
Search our complete archive of awarded project abstracts to learn about what NASA has funded
Still have questions? Visit the program FAQs
","programId":73,"responsibleMd":{"acronym":"STMD","canUserEdit":false,"city":"","external":false,"linkCount":0,"organizationId":4875,"organizationName":"Space Technology Mission Directorate","organizationType":"NASA_Mission_Directorate","naorganization":false,"organizationTypePretty":"NASA Mission Directorate"},"responsibleMdId":4875,"stockImageFileId":36648,"title":"Small Business Innovation Research/Small Business Tech Transfer"},"lastUpdated":"2024-1-10","releaseStatusString":"Released","viewCount":53,"endDateString":"Nov 2013","startDateString":"May 2013"},"infoText":"Advanced from another project within the program","infoTextExtra":"Another project within the program (Low Cost Automated Manufacture of High Efficiency THINS ZTJ PV Blanket Technology (P-NASA12-007))","dateText":"April 2014"}],"primaryImage":{"file":{"fileExtension":"jpg","fileId":302753,"fileSizeString":"0 Byte"},"id":299298,"description":"Low Cost Automated Manufacture of PV Array Technology (P-NASA12-007-1), Phase II","projectId":17750,"publishedDateString":""},"responsibleMd":{"acronym":"STMD","canUserEdit":false,"city":"","external":false,"linkCount":0,"organizationId":4875,"organizationName":"Space Technology Mission Directorate","organizationType":"NASA_Mission_Directorate","naorganization":false,"organizationTypePretty":"NASA Mission Directorate"},"program":{"acronym":"SBIR/STTR","active":true,"description":"The NASA SBIR and STTR programs fund the research, development, and demonstration of innovative technologies that fulfill NASA needs as described in the annual Solicitations and have significant potential for successful commercialization. If you are a small business concern (SBC) with 500 or fewer employees or a non-profit RI such as a university or a research laboratory with ties to an SBC, then NASA encourages you to learn more about the SBIR and STTR programs as a potential source of seed funding for the development of your innovations.
The SBIR and STTR programs have 3 phases:
The SBIR and STTR Phase I contracts last for 6 months with a maximum funding of $125,000, and Phase II contracts last for 24 months with a maximum funding of $750,000 - $1.5 million.
Opportunity for Continued Technology Development Post-Phase II:
The NASA SBIR/STTR Program currently has in place two initiatives for supporting its small business partners past the basic Phase I and Phase II elements of the program that emphasize opportunities for commercialization. Specifically, the NASA SBIR/STTR Program has the Phase II Enhancement (Phase II-E) and Phase II eXpanded (Phase II-X) contract options.
Please review the links below to obtain more information on the SBIR/STTR programs.
Provides an overview of the SBIR and STTR programs as implemented by NASA
Provides access to the annual SBIR/STTR Solicitations containing detailed information on the program eligibility requirements, proposal instructions and research topics and subtopics
Schedule and links for the SBIR/STTR solicitations and selection announcements
Federal and non-Federal sources of assistance for small business
Search our complete archive of awarded project abstracts to learn about what NASA has funded
Still have questions? Visit the program FAQs
","programId":73,"responsibleMd":{"acronym":"STMD","canUserEdit":false,"city":"","external":false,"linkCount":0,"organizationId":4875,"organizationName":"Space Technology Mission Directorate","organizationType":"NASA_Mission_Directorate","naorganization":false,"organizationTypePretty":"NASA Mission Directorate"},"responsibleMdId":4875,"stockImageFileId":36648,"title":"Small Business Innovation Research/Small Business Tech Transfer"},"leadOrganization":{"canUserEdit":false,"city":"San Diego","country":{"abbreviation":"US","countryId":236,"name":"United States"},"countryId":236,"external":true,"linkCount":0,"organizationId":3428,"organizationName":"Vanguard Space Technologies, Inc","organizationType":"Industry","stateTerritory":{"abbreviation":"CA","country":{"abbreviation":"US","countryId":236,"name":"United States"},"countryId":236,"name":"California","stateTerritoryId":59},"stateTerritoryId":59,"ein":"853830624 ","naorganization":false,"organizationTypePretty":"Industry"},"supportingOrganizations":[{"acronym":"GRC","canUserEdit":false,"city":"Cleveland","country":{"abbreviation":"US","countryId":236,"name":"United States"},"countryId":236,"external":false,"linkCount":0,"organizationId":4860,"organizationName":"Glenn Research Center","organizationType":"NASA_Center","stateTerritory":{"abbreviation":"OH","country":{"abbreviation":"US","countryId":236,"name":"United States"},"countryId":236,"name":"Ohio","stateTerritoryId":23},"stateTerritoryId":23,"naorganization":false,"organizationTypePretty":"NASA Center"}],"statesWithWork":[{"abbreviation":"CA","country":{"abbreviation":"US","countryId":236,"name":"United States"},"countryId":236,"name":"California","stateTerritoryId":59},{"abbreviation":"OH","country":{"abbreviation":"US","countryId":236,"name":"United States"},"countryId":236,"name":"Ohio","stateTerritoryId":23}],"lastUpdated":"2024-1-10","releaseStatusString":"Released","viewCount":156,"endDateString":"Oct 2016","startDateString":"Apr 2014"}}