5M: Flexible solar panels

6/2/2024

5M is developing a flexible solar panel with a higher energy output and lower weight compared to fixed panels. These panels will be used primarily in telecommunications satellites in geostationary orbit, but their applications are broad, including navigation and observation satellites, space travel and scientific missions. The flexible part of the panel is made from 5M's thin composites, while the rigid part combines lightweight alloys and rigid composite structures.

The primary objective of the project is to develop a distinctive flexible solar panel subsystem that offers enhanced energy output compared to conventional fixed solar panels, while reducing weight and overall volume. Flexible solar panels will be utilized primarily in telecommunications satellites operating in geostationary Earth orbit, with applications extending to navigation and Earth observation, deep space travel, and ambitious scientific missions.

The flexible component of the solar panel is comprised of a proprietary ultra-thin composite material, developed and manufactured by 5M. The rigid component is a combination of lightweight non-ferrous metal alloys and rigid composite structures. The length of the solar panel is up to 30 meters. The entire mechanical subsystem is completed by 5M.

The Engineering Model (EM) phase of the mechanical subsystem of the flexible solar panels, which are part of Thales Alenia Space's new versatile telecommunications satellite platform, is currently being finalized and tested.

At the same time, a complementary project called Critical Building Block is underway to develop, test, and manufacture a new generation of flexible solar panels, including a flexible photovoltaic assembly to replace the current generation under development in the NOVACOM II project. The objective is to enhance the power-to-weight ratio of the solar panel by at least 25% in comparison to the flexible solar panels currently under development. The new generation of building blocks for the flexible panel assembly will include modular blankets for multi-wing concepts, a lightweight solar panel winding system, and a weight-optimized solar panel tilt arm. The optimization of the power-to-weight ratio is evident in the assembly's compactness, cost savings, and the new ability to operate in partial deployment and retraction mode of the flexible solar panels.

ESA has appointed 5M to oversee this project, and 5M will then manufacture and test all the optimized elements. It is working with Thales Alenia Space France (design concept), Thales Alenia Space Belgium (feasibility of subsequent solar cell integration), and LK Engineering, which is responsible for the detailed design.

Finally, the merger of the Novacom II and Critical Building Blocks projects is underway. The goal is to implement the new lightweight solutions developed in Critical Building Blocks while maintaining the existing design, which has already undergone mechanical analysis and functional testing. The new, lighter and more powerful flexible solar panel, designated Gen 1.5, is expected to replace the original concept without a significant shift in the production schedule for flight units.