Lightweight Solar for Spacecraft

Challenge

Project IKAROS required an ultra-lightweight solar solution to power onboard instruments during deep-space travel. The solar panels had to withstand launch, deployment, and long-duration exposure while maintaining extreme power-to-weight efficiency. Every gram and every watt mattered.

Approach

PowerFilm collaborated with the mission team to design custom solar panels for direct sail integration. A 25µm substrate and optimized cell configuration minimized weight while delivering the required bus voltage. The result was a high-efficiency design exceeding 1200 W/kg, with reduced wiring mass and robust deployment performance.

Solution

The custom solar array successfully powered onboard instruments throughout the mission to Venus and beyond. PowerFilm’s lightweight amorphous silicon technology enabled extreme power-to-weight performance in one of the most demanding environments possible.