In-Space Manufactured Solar Array providing highly cost-efficient power generation for SmallSats and In-Orbit Servicing; enabling European non-dependence and competitiveness in space technologies

Project Information

ISM4Europe

Grant agreement ID: 101188622

DOI

10.3030/101188622

EC signature date 30 November 2024

Start date 1 December 2024

End date 30 November 2026

Funded under

• The European Innovation Council (EIC)

Total cost

No data

EU contribution

€ 2 499 999,00

Coordinated by

DCUBED GMBH
Germany

Periodic Reporting for period 1 - ISM4Europe (In-Space Manufactured Solar Array providing highly cost-efficient power generation for SmallSats and In-Orbit Servicing; enabling European non-dependence and competitiveness in space technologies)

Reporting period: 2024-12-01 to 2025-11-30

Summary of the context and overall objectives of the project

Europe’s space sector is facing a structural challenge: rapidly growing demand for on-orbit power, driven by larger and more capable satellites, is constrained by launch-limited architectures, complex deployment mechanisms, and dependence on non-European supply chains. Traditional solar arrays are designed for launch survivability rather than on-orbit performance and scalability, limiting Europe’s competitiveness in the emerging “new space” market.

The ISM4Europe project addresses this challenge by advancing in-space manufacturing (ISM) of large solar arrays using Dcubed’s photopolymer-based technology. By manufacturing and deploying structures directly in orbit, the project aims to decouple solar array size and power capability from launch vehicle constraints, while reducing system complexity and enabling scalable power generation beyond current state-of-the-art solutions.

The project’s core objective is to derisk and validate ISM solar array technology through progressive in-orbit demonstration missions, while preparing the European market for commercial uptake. This includes advancing the technology from early demonstration hardware toward flight-qualified, scalable solar array products in the multi-kilowatt class, addressing the needs of the majority of the satellite market.

Within the broader political and strategic context, ISM4Europe contributes directly to European technological sovereignty, resilience of space infrastructure, and competitiveness in high-power satellite platforms. The expected impacts include increased on-orbit power availability, reduced dependence on critical non-EU suppliers, and the creation of a new European industrial capability in space manufacturing. At scale, ISM solar arrays have the potential to enable new mission classes and support Europe’s long-term space autonomy.

Work performed from the beginning of the project to the end of the period covered by the report and main results achieved so far

During the reporting period, work was performed across project management, commercial preparation, and technical development work packages.

On the project management side, the team was significantly strengthened, with headcount increased by 43% to support parallel technology, mission, and commercial activities. The project’s intellectual property position was reinforced through the filing of three additional patent applications covering key aspects of the ISM technology. Technical and programmatic risks were continuously reviewed, leading to a reduction of risks related to system integration and technology scalability. During this period, a supply risk related to the availability of suitable solar cells materialised; mitigation measures were defined and implemented to preserve the project timeline and technical objectives.

On the commercial side, extensive market research and customer engagement activities were conducted. Based on clear demand signals and improved price–performance projections, the initial market entry point was pivoted from 500 W to 2 kW class solar arrays. In parallel, the project supported the launch of the ARAQYS product brand, including the development of a new corporate identity, branding, and website, designed to accommodate a growing portfolio of ISM missions and products.

Technically, the solar array architecture was significantly advanced. A key achievement was the transition from a purely photopolymer-based structural concept to a hybrid architecture using CFRP substrates combined with the ISM process. This change improved structural performance, scalability, and manufacturability while maintaining the advantages of in-space manufacturing. Design consolidation, material trade-offs, and system-level definition were progressed; environmental test campaigns such as thermal cycling were defined but not yet executed and are planned for subsequent phases.

Progress beyond the state of the art and expected potential impact (including the socio-economic impact and the wider societal implications of the project so far)

ISM4Europe delivers results that go beyond the current state of the art by demonstrating a fundamentally new approach to solar array manufacturing and deployment. Unlike deployable rigid or flexible arrays, the ISM concept removes launch-induced size constraints and enables continuous scaling of power output through on-orbit fabrication.

The project advances novel composite architectures, bonding processes, and material combinations specifically designed for in-space manufacturing. These results open a pathway toward solar arrays in the multi-kilowatt range and beyond, addressing a critical gap in the current European space power ecosystem.

For further uptake and success, key needs include continued in-orbit demonstration at higher power levels, qualification of alternative terrestrial solar cells for space use to mitigate supply chain constraints, and access to dedicated launch opportunities to increase schedule control. Additional enablers include supportive regulatory frameworks for ISM-produced space hardware, standardisation of interfaces, and continued IPR protection.

In the final phase, the results provide a clear overview of a scalable, commercially viable ISM solar array product line, positioning Europe at the forefront of in-space manufacturing technologies.