Here at Airborne we try not to get too carried away. But being market leader in Europe in manufacturing solar-array substrate panels, and still growing, we were selected by SpaceTech GmbH in Immenstaad (STI) to manufacture the Jason-CS-A panels. Airborne was thrilled to be selected and working together with STI for the first time. And now the panels are ready to transport. Let me give you some sneak-peak insights on what we did …
What Jason-CS-A panels have got to do with climate change
This project is not just about ‘another satellite’: this project adds very important knowledge about the climate changes on our planet as the Jason-CS-A panels are part of The Jason Continuity of Service (Jason-CS) mission. This mission on the Sentinel-6 spacecraft is an international partnership between the United States and Europe. Jason-CS/Sentinel-6 includes two identical satellites scheduled to launch in 2020 (satellite A) and 2025 (satellite B). These satellites will carry the record of sea level change – used by agencies, oceanographers, climate scientists, and many more – into its fourth decade.
Jason-CS/Sentinel-6 will ensure continuity of sea level observations for at least a decade. Like their predecessors, these satellites will provide ongoing measurements of global sea level rise – one of the most important impacts of human-caused climate change. The data will also support operational oceanography, improving forecasts of ocean currents as well as wind and wave conditions. In addition, it will help to improve forecasts of weather conditions likely to prevail two to four weeks ahead (e.g., hurricane intensity forecasting) and in the next season (e.g., El Niño, La Niña).
(source: https://sealevel.jpl.nasa.gov/missions/jasoncsnew/)
By delivering the substrates, we contribute to one of the most important researches on human-caused climate change.
New panels, new inserts
The goal of the project is to deliver two flight models to STI. One flight model is built out of four panels (two on each side). Before manufacturing a qualification phase has been performed with all the partners.
What made this project even more interesting for us is that there were new features in the design. So, we tested multiple samples and proved that our heritage process was also suitable for the Jason project, well almost…
When we looked at the design of the inserts, we saw that some of these inserts are sometimes heavy loaded (more than 200kg on a M5 insert) in several places. During qualification our samples failed, the reason was a combination between our heritage and the design. So we improved on process and design together with STI and performed new qualifications tests which ultimately were successful.
The thing is: It is hard to imagine the work you need to do before you can even start production. What are the requirements? What kind of test do we need to perform? What is acceptable? Who are involved in the decisions? And so on. In the end the project team managed all the challenges that we have faced during this program. The basis for solving this challenges was to work in close cooperation with our new client STI.
Good things come to those who qualify and manufacture
During the program we noticed our co-operation with STI was getting better and better. So now, after two years of developing, qualifying and manufacturing Airborne have delivered two complete flight sets to STI! And our client was very happy. This is what Mr. Anton Zhukov, project manager of Jason Solar Array project at STI said to us: “The production of the substrates in such a size was for sure a challenge, especially considering the demanding and strict requirements for solar array application – limited mass, high strength and special insulation and cleanliness properties. And this complicated task was excellently mastered by Airborne. The production of the substrates is a very important base for the next steps of solar array production.The first satellite will be launched in 2020. And of course Airborne can´t wait to work on more projects together with STI.
Want to know more about our work on panels? Please contact Sandor Woldendorp.
