Toray Advanced Composites to supply composites for constellation solar arrays

Toray’s space qualified epoxy-based, carbon fibre-reinforced materials will be manufactured and supplied from Toray Advanced Composites’ European Centre of Excellence for thermoset systems in Langley Mill, UK. Airborne will use them to manufacture solar array substrates and yoke panels. Toray’s high-performance materials, which have been produced to tight tolerances on fibre areal weight, resin content and slit width, will be supplied in 6-inch (15cm) wide unidirectional prepreg tape format so that they are sufficiently effective for their intended use. There will be a high-volume production run using Airborne’s robotic Automated Tape Laying (ATL) technology, which has been specifically developed for space applications.

“With over 40 years of space-flight heritage, Toray is proud to support the next generation of LEO satellite constellations with our flight-proven material systems,” states Claire Baker, Development Lead, Space & Comms, Toray Advanced Composites. “Our lightweight composites offer the ideal combination of high stiffness, excellent toughness, and low outgassing—which when combined with their proven inflight reliability makes them perfectly suited for demanding space environments and for automated, scalable manufacturing.”

Ms Baker continues, “As the space sector moves toward high-rate production, automation is key. Airborne demonstrates how advanced carbon fibre composites and smart manufacturing enable the performance, scalability and affordability needed to expand global access to space.”

Sandor Woldendorp, Director Aerospace, Airborne “This LTA is the result of many years of close collaboration between Toray and Airborne on the development and manufacturing of spacecraft structures. Our companies share a vision on making composites affordable and scalable for new space.”

Airborne had signed in January a contract with Airbus Netherlands B.V. to supply panel and yoke substrates for the Sparkwing solar arrays that the company is providing for MDA AuroraTM mega-constellation satellites.

about Toray Advanced Composites
Toray Advanced Composites is a leader in the development and production of advanced thermoplastic and thermoset composite materials. The broad product portfolio is incorporated in high-performance products for aerospace, space, communications, automotive, consumer, and industrial applications. Toray Advanced Composites has a long heritage of combining state-of-the-art materials technology with world-class technical expertise to deliver a unique customer-centric business model. Production and operation facilities are in North America, Europe, and Asia. Toray Advanced Composites is a subsidiary of the Toray Group.

about Airborne
Airborne is market leader in the manufacturing of solar-array substrate panels in Europe, making sandwich panels for ESA missions, small sats and constellations. Airborne’s proprietary automation is applied in the manufacturing of satellite constellation panels as well as micro-launcher structures.