Development and testing of the DEAR 100W flexible solar array blanket

Advances in Space Research

Abstract

The growing trend toward smaller, more compact satellites increases the demand for lightweight, deployable solar arrays. In response, the DEAR project - funded under ESA contract no. 4000133890/21/NL/MM/ra as part of the ARTES 4.0 programme - developed and tested a deployable 100 W solar array designed to fit within a single CubeSat segment. Beyond strict volume constraints, the most critical requirement was ensuring a minimum operational lifetime of 5 years, with an end-of-life (EOL) power output of 100 W. To guide material selection and mechanical as well as electrical sizing, this paper defines multiple reference mission scenarios and analyzes key space environment factors - such as radiation, atomic oxygen erosion, and thermal loads. Based on this analysis, the design ensures 100 W power output at EOL, even under worst-case conditions. The array was manufactured using a semi-automated welding process for electrical interconnections, with a coated FEP supporting film for atomic oxygen resistance and polyimide reinforcements for mechanical robustness. Triple-junction GaAs solar cells were used as photovoltaic devices. As part of the DEAR system, the blanket underwent a qualification test campaign, including vibration and thermal-vacuum tests. This paper presents performance evaluations through multiple deployments, power output measurements (including IV-curve analysis), and electroluminescence inspections. This work establishes a validated design and manufacturing process for a flexible solar array blanket, qualified through extensive testing for diverse space mission scenarios.

Authors 5

1. Sven Holz corresponding

   Deutsches Zentrum für Luft- und Raumfahrt e. V. (DLR)

   Affiliation as printed

   Mechanics and Thermal Systems, DLR Institute of Space Systems, Robert-Hooke-Straße 7, Bremen, 28359, Germany

2. Patric Seefeldt

   Deutsches Zentrum für Luft- und Raumfahrt e. V. (DLR)

   Affiliation as printed

   Mechanics and Thermal Systems, DLR Institute of Space Systems, Robert-Hooke-Straße 7, Bremen, 28359, Germany

3. Kaname Sasaki

   Deutsches Zentrum für Luft- und Raumfahrt e. V. (DLR)

   Affiliation as printed

   Mechanics and Thermal Systems, DLR Institute of Space Systems, Robert-Hooke-Straße 7, Bremen, 28359, Germany

4. Tom Spröwitz

   Deutsches Zentrum für Luft- und Raumfahrt e. V. (DLR)

   Affiliation as printed

   Mechanics and Thermal Systems, DLR Institute of Space Systems, Robert-Hooke-Straße 7, Bremen, 28359, Germany

5. Yahya Motemani Aachen Saint-Gobain Research Germany

   Saint-Gobain (Germany)

   Affiliation as printed

   Saint-Gobain Research Germany, Glasstraße 1, Herzogenrath, 52134, Germany