Integration techniques for space solar arrays have evolved only incrementally since the 1970's due to the strong affinity for heritage processes. Construction of the photovoltaic assembly (PVA - i.e. the `solar blanket' comprising solar cells, interconnects, coverglass, i.e. “CIC's”, and laydown adhesive on to the structural substrate) has changed little, using custom labor intensive processes that are fundamentally unreliable and expensive. The need for very large next generation (~300 kW) solar arrays to convert energy for solar electric propulsion magnifies the inadequacies in cost and repeatability of these manual processes. We describe the development of innovative solutions to automating the assemblies of PVA's for space and demonstrated their implementation using Coplanar Front Contact (CFC) solar cells and conventional semiconductor manufacturing equipment.

Implementing new solar panel technology is often hampered by the difficulty in obtaining flight heritage and integrating experimental technology into conventional panels. Modular solar panel technology overcomes this limitations by allowing substitution of an experimental module into a modular flight arrays using mostly conventional modules. The approach also allows the benefits of full-scale testing when test article sizes are limited, and easier repairability by allowing damaged modules to be unplugged and repaired off-line. The Modular Solar Array with Integrated Construction (MOSAIC) technology described in this paper is being flight tested on an experiment called MATRS (Modular Array Technology for Reconfigurable Spacecraft). The flight test unit includes modules with conventional space cells, as well as advanced modules incorporating 4-junction IMM cells to demonstrate the ease of ground integration and replacement of the modular approach, incorporation of experimental modules in flight, and life cycle performance.