The Challenge: Keeping Up with Satellite Constellation Demand
The satellite communications industry is expanding at an unprecedented pace. SpaceX’s Starlink alone doubled its user base from 2023 to 2024, reaching 4.3 million users. To meet the surging demand for global connectivity, more satellite constellations are being developed worldwide. In August 2024, China’s Thousand Sails mega-constellation launched its first 18 satellites and aims to deploy 600 more by the end of 2025. Meanwhile, in Europe, the European Commission and ESA have committed to the IRIS² constellation, which will add 290 satellites to low and medium Earth orbit.
But with this rapid expansion comes a significant challenge: how do manufacturers keep up with the demand for high-volume, low-cost, high-quality satellite production?
Imagine you are a satellite manufacturer gearing up for a new constellation. You need to scale production up quickly, but hiring and training skilled labour takes time. Supply chain constraints and rising material costs add further pressure. Delays in manufacturing could mean missing critical launch windows, may result in penalties, impacting your entire business case. Relying on traditional manufacturing methods is no longer a viable option in an industry where speed is crucial while attaining cost efficiency and reliability is a must.
The role of automation in satellite manufacturing
If you are involved in satellite manufacturing, you have likely faced these challenges:
- How can I produce satellites at scale without sacrificing quality?
- How do I keep costs under control while increasing output?
- How do I ensure my production process is future-proof as demand continues to rise?
Automation provides the answer. By integrating automated production lines, satellite manufacturers can achieve:
- Faster turnaround times – Automated processes significantly reduce production time compared to traditional manual methods.
- Consistent, high-quality output – Robotics and automation ensure precision and repeatability, minimizing defects.
- Lower production costs – Reducing manual labour requirements leads to cost savings and improved efficiency.
- Scalability – Automated manufacturing lines can ramp up production quickly to meet market demands.
For example, automated composite manufacturing processes, such as those used for solar array substrates, allow for high-precision, repeatable production at scale. The use of robotics and digital manufacturing techniques eliminates many of the inefficiencies associated with manual layup processes, reducing errors and material waste while improving structural performance.
Is your production line ready for the future?
With new mega-constellations launching every year, the industry shows no signs of slowing down. Amazon’s Kuiper System has 3,236 satellites in the pipeline, MDA Space is manufacturing satellites for Globalstar’s Apple-backed constellation, and multiple next-generation LEO constellations are in development.
The question is: how prepared is your production line to meet this growing demand? Are you relying on traditional, labour-intensive methods that may soon become obsolete? Or are you exploring automation to gain a competitive edge?
Let’s talk about scalable production
At Airborne, we specialize in automation for composite manufacturing, particularly for satellite components like solar array substrates. With over 400 flight panels delivered and more than 200 currently in orbit, we have firsthand experience in scaling production for demanding satellite programs. Our expertise in automated composite manufacturing ensures that as demand grows, production can keep pace—without compromising quality.
Our dedicated constellation manufacturing line is in its final development phase, designed to support high-volume, high-quality satellite production. A testament to our capability is our recent partnership with Airbus Netherlands. In December 2024, we were selected to supply 700 solar array substrates for the MDA AURORATM mega-constellation. Delivering this volume within just two years would not be possible without our advanced automation solutions.
If you’re looking to scale your operations, reduce costs, and improve efficiency, we can help.
Want to learn how automation can transform your production process? Get in touch with Burak Cakir, our Business Development Manager, to explore the possibilities.
