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Roll Out Solar Array

A Roll-Out Solar Array (ROSA) is a lightweight, flexible solar array technology designed for space applications, featuring photovoltaic blankets that roll up compactly around deployable composite booms for efficient launch stowage and autonomous deployment without motors.^[1]^[2] Developed primarily by NASA in partnership with Deployable Space Systems, Inc. (DSS, now part of Redwire Space), ROSA emerged from Small Business Innovation Research (SBIR) awards funded between 2009 and 2013, with initial ground demonstrations in 2014 under NASA's Game Changing Development program.^[1] The technology addresses limitations of traditional rigid-panel solar arrays by offering up to a 400% reduction in stowage volume and a 20% reduction in mass, while achieving significantly higher power density in stowed configuration through its scalable, modular design using thin-film solar cells on a flexible substrate.^[2]^[3] Key advantages include autonomous deployment via stored strain energy in the composite booms, which flatten and roll for storage before expanding to support the array, enabling reliable operation in low-gravity environments and reducing complexity and cost compared to motorized systems.^[1]^[4] Each ROSA unit can generate over 20 kW of power when deployed to dimensions of approximately 6 m by 13.7 m, with scalability to larger arrays exceeding 30 kW per panel for high-power missions.^[2]^[1] Notable applications include the International Space Station (ISS), where the first ROSA prototype launched on June 3, 2017, via SpaceX CRS-11 and successfully deployed on June 18, 2017, demonstrating its viability despite a later retraction issue leading to jettison on June 26, 2017.^[2] By 2023, six upgraded iROSAs (integrated ROSAs) were installed on the ISS, adding approximately 120 kW of power and increasing total station capacity to about 215 kW (a 30% increase); as of 2025, six iROSAs remain installed, with an additional pair delivered for future deployment.^[1] ROSA technology has also powered NASA's Double Asteroid Redirection Test (DART) mission, launched November 24, 2021, marking its first use on a planetary defense spacecraft, and is slated for the Lunar Gateway's Power and Propulsion Element, providing 60 kW for deep-space operations.^[1] Commercially, it has been integrated into satellites by companies like Maxar Technologies, highlighting its transition from government research to broader aerospace use.^[1]

Design and Technology

Components and Materials

Roll Out Solar Arrays (ROSA) feature a core structure comprising a flexible photovoltaic blanket, deployable composite booms, and a central roller mandrel for stowage. The photovoltaic blanket, termed the Integrated Modular Blanket Assembly (IMBA), consists of a tensioned orthogonal open-weave backplane fabricated from lightweight S-glass fibers, which supports strings of photovoltaic cells, electrical harnesses, and protective foam layers to enhance durability in space environments.^[5] The booms are high-strain composite slit-tube elements made from carbon fiber reinforced polymers, providing structural support and utilizing stored elastic energy for unrolling without motors.^[5] The mandrel serves as the roller mechanism around which the blanket is coiled for launch, enabling compact packaging.^[5] Key materials emphasize flexibility, low mass, and high performance. The solar cells are ultra-thin triple-junction gallium arsenide (GaAs) devices, such as Boeing Spectrolab's XTJ Prime cells, achieving conversion efficiencies around 30-32% under space conditions to maximize power from limited area.^[6] These cells are adhered to a flexible polymer substrate, typically Kapton polyimide film, which offers electrical insulation, resistance to thermal extremes, and bend radius compatibility for repeated rolling without degradation.^[6] The booms employ carbon fiber composites for their high stiffness-to-weight ratio, ensuring rigidity post-deployment while maintaining a low overall array mass.^[7] For standard configurations like the ISS Roll Out Solar Array (iROSA), the stowed volume is approximately 0.6 m in diameter by 5 m in length, allowing integration into launch vehicle constraints, while the deployed area reaches about 19 m by 6 m to provide up to 28 kW of beginning-of-life power output per wing.^[1]^[8] This design yields a high power density, with the iROSA delivering over 20 kW in operational ISS use, supported by the 30% efficient multi-junction cells.^[9] Wiring and connectors are embedded within the IMBA blanket, featuring flexible harnesses that route generated electricity to the spacecraft bus, minimizing mass and ensuring reliable output across voltage ranges from 12 V to over 300 V.^[5]^[10]

Deployment Mechanism

The deployment mechanism of the Roll Out Solar Array (ROSA) enables automated unrolling in space through stored strain energy in composite slit-tube booms, ensuring gravity-independent operation without motors or manual intervention. The array is initially stowed in a compact cylindrical form around a mandrel, with the booms flattened and coiled alongside the photovoltaic blanket for launch. Upon activation, the booms recover their natural cylindrical shape, driving the extension and unrolling of the blanket while providing structural support.^[11]^[1] The step-by-step deployment sequence commences with the release of restraints, allowing initial boom extension that initiates unrolling of the integrated modular photovoltaic blanket assembly (IMBA) from the mandrel. As the booms elongate, they exert controlled tension to unroll and flatten the blanket into a planar configuration, with the process culminating in latching at the root structure for operational stability. This passive actuation leverages the booms' elastic recovery, monitored by onboard sensors including accelerometers for tension and alignment, and cameras for visual confirmation of deployment progress.^[11]^[5] Central to the mechanism are slit-tube booms constructed from high-strain composite laminates, featuring a helical slit design that facilitates coiling while enabling self-rigidization upon extension—the booms snap into a rigid cylindrical form, serving as both actuators and load-bearing elements. The mandrel incorporates rollers for smooth stowage; retraction capability, including a motorized linear actuator and lanyard system for controlled rollback, was demonstrated in the ROSA prototype but is not a feature of operational iROSA units.^[5]^[11] Deployment dynamics are analyzed using finite element models to predict loads and kinematics, with a basic approximation for boom extension force derived from beam theory: F = \frac{E I}{L^2} \delta, where E is the modulus of elasticity, I is the moment of inertia of the boom cross-section, L is the deployed length, and \delta is the lateral deflection; this equation informs the force balance during unrolling, supplemented by advanced simulations in Abaqus or Ansys for full-system validation including laminate stiffness matrices.^[5]^[11] Ground testing validates the mechanism through vacuum chamber simulations replicating space conditions, including thermal cycling and partial deployments of engineering development units (EDUs) to assess reliability, kinematics, and potential anomalies like uneven tension. Full orbital deployment per wing typically requires 10-15 minutes, allowing rapid extension while minimizing dynamic disturbances.^[11]^[5]

Advantages and Limitations

Performance Benefits

Roll-out solar arrays (ROSAs) offer superior packaging efficiency compared to rigid panel alternatives, achieving stowed power densities of approximately 40 kW/m³, which represents a significant improvement over the 5-10 kW/m³ typical of conventional rigid arrays, enabling up to a fourfold reduction in launch volume for equivalent power output.^[10]^[12] This compactness stems from the rollable blanket design, allowing scalability to larger arrays, such as the 60 kW wings developed for the Lunar Gateway's Power and Propulsion Element, where fixed deployment infrastructure mass becomes a smaller fraction of the total.^[1] Additionally, ROSAs exhibit lower mass, with specific powers reaching 225 W/kg at beginning-of-life under air mass zero (AM0) conditions for a 25 kW configuration, translating to roughly 4.4 kg/kW, a notable decrease from the 10-15 kg/kW of older rigid systems.^[13] In terms of power generation, ROSAs deliver deployed power densities of 200-300 W/m² at beginning-of-life, leveraging high-efficiency inverted metamorphic (IMM) solar cells with efficiencies up to 33.7%.^[13]^[12] The overall array efficiency can be expressed as \eta = \frac{P_\text{out}}{A \cdot I_s}, where P_\text{out} is the output power, A is the deployed area, and I_s is the solar irradiance (typically 1366 W/m² under AM0 conditions); this metric highlights how ROSAs maintain high \eta values (around 28% end-of-life for blankets) despite their flexible structure.^[13] For instance, upgraded ISS ROSA (iROSA) wings generate over 28 kW each at beginning-of-life, enabling up to a 30% total power increase for the station with the installation of six iROSAs as of 2023 while occupying half the stowed volume of legacy arrays.^[1] The flexible nature of ROSAs enhances environmental resilience, particularly against micrometeoroids and orbital debris, as the blanket's inherent flexibility and redundant cell layout localize damage, preventing catastrophic failure unlike brittle rigid panels.^[1] Composite booms further bolster durability in harsh space conditions, including radiation and thermal extremes.^[1] Cost-effectiveness arises from reduced launch mass and simplified deployment without motors, potentially saving $10-20 million per megawatt through lower payload integration and transportation expenses, based on current launch costs of approximately $10,000 per kg.^[1]^[13] Prototype testing of the initial ROSA unit on the International Space Station in 2017 demonstrated reliable performance, producing power as expected without significant degradation post-deployment.^[11]

Engineering Challenges

One of the primary engineering challenges in developing roll-out solar arrays (ROSAs) is managing dynamic instabilities during the unrolling process, such as fluttering of the array edges caused by uneven tensioning or interactions with deployment mechanisms.^[14] These instabilities can lead to vibrations with frequencies around 0.6–0.7 Hz for edge flaps and 0.41 Hz for the first bending mode, potentially compromising structural integrity if not controlled.^[14] Thermal expansion mismatches in orbit represent another key hurdle, as temperature variations from day-night cycles induce frequency shifts in the array's natural modes, for example, from 0.91 Hz during daylight to 1.21 Hz at night, stressing the flexible blanket and booms.^[14] Additionally, degradation from atomic oxygen exposure in low-Earth orbit erodes polymeric materials in the array blanket, reducing optical properties and electrical performance over time.^[15] To mitigate these issues, damping systems integrated into the booms control deployment rates and suppress vibrations, ensuring stable unrolling without excessive oscillations.^[14] Redundant cell strings provide fault tolerance by organizing photovoltaic elements into parallel configurations, allowing continued operation if individual strings fail due to micrometeoroid impacts or radiation.^[16] Protective coatings, such as silicon oxide layers, are applied to the array surfaces to resist atomic oxygen erosion, preserving material integrity and minimizing mass loss during exposure.^[15] Reliability assessments from vacuum simulations demonstrate low failure rates, with less than 1% cell damage observed under combined thermal-vacuum and radiation conditions, highlighting the robustness of the flexible design.^[17] Thermal stresses contributing to array integrity challenges are quantified by the equation for induced stress:

\sigma = \alpha \cdot \Delta T \cdot E

where \sigma is the thermal stress, \alpha is the coefficient of thermal expansion, \Delta T is the temperature change (typically ranging from -60°C to +60°C in simulations), and E is the material's Young's modulus; this relation underscores the need for matched expansion coefficients between the blanket and booms to avoid buckling or delamination.^[18]^[17] Ground testing has revealed outcomes like partial jams in early prototypes due to latch misalignments or insufficient offloading of gravitational effects, which were resolved through iterative design refinements such as enhanced boom rigidity using high-strain composite materials.^[14] Orbital tests confirm these mitigations, showing successful deployments in approximately 3.5 minutes but occasional retraction difficulties from similar alignment issues, addressed via redundant mechanisms.^[14] Long-term concerns include end-of-life power retention, projected at 80-90% after 15 years based on observed degradation rates below 0.8% annually from environmental factors like radiation and atomic oxygen.^[19]

Development History

Patents and Early Concepts

The concept of roll-out solar arrays traces its origins to the 1960s, evolving from early developments in furlable antenna structures for spacecraft. These deployable technologies, which emphasized compact stowage and reliable extension in space, inspired adaptations for photovoltaic applications. A seminal early patent, U.S. Patent 3,473,758 issued in 1969 to inventor Herman P. Valentijn and assigned to NASA, described a roll-up solar array featuring arcuate solar panels furled on a tapered drum for launch storage. The design allowed panels to extend arcuately around a spacecraft upon deployment, stiffened by hollow beams that flattened for coiling and regained shape through elastic recovery, with serrations to manage stress during unrolling.^[20] By the 1990s and into the 2000s, Department of Defense studies explored rollable photovoltaics to enhance spacecraft power efficiency and packaging density. These efforts focused on flexible substrates and strained composite booms for high specific power in military applications. NASA complemented this with research at Glenn Research Center, investigating high-power flexible arrays for deep space missions, emphasizing lightweight materials and autonomous deployment. Primary credits for advancing these ideas went to engineers like Kenneth A. Ray at Hughes Aircraft in the 1960s for large-area deployable arrays, and later collaborations between NASA and partners such as Lockheed Martin for structural innovations.^[21]^[22] A pivotal modern patent, U.S. Patent 8,683,755 B1 issued in 2014 to inventors Brian R. Spence and Stephen F. White and assigned to Deployable Space Systems, Inc. (DSS), detailed a directionally controlled elastically deployable roll-out solar array. Key claims covered longitudinal elastic booms that self-deploy using stored strain energy for unidirectional extension, controlled by rollers or lanyards, alongside a flexible photovoltaic blanket tensioned independently via springs or motors to avoid coupling stresses. This built on prior concepts without overlapping later implementations, prioritizing compact rolling for launch. The patent's influence extended through NASA's Small Business Innovation Research (SBIR) funding starting in 2009, enabling DSS to commercialize the technology; by 2017, it supported AFRL-NASA flight demonstrations, and subsequent licensing facilitated adoption by entities like Redwire following DSS's 2021 acquisition.^[23]^[1]

ROSA Prototype Testing

The Roll Out Solar Array (ROSA) prototype development was initiated by NASA in 2012 through a contract awarded to Deployable Space Systems (DSS) to advance lightweight solar array technologies for solar electric propulsion applications.^[2] Ground testing commenced in the mid-2010s, with early evaluations focusing on structural and environmental performance at facilities including NASA Glenn Research Center, where collaboration supported qualification efforts for spaceflight.^[2] Key ground tests involved thermal vacuum chamber deployments at the Arnold Engineering Development Complex (AEDC), simulating extreme space conditions such as temperatures from -324°F to 223°F over accelerated 15-year geosynchronous orbit timelines, achieving full array extension without mechanical failure.^[24] These ground validations transitioned to the pivotal 2017 in-space demonstration on the International Space Station (ISS), launched aboard SpaceX's CRS-11 mission on June 3 and deployed via the Canadarm2 robotic arm on June 18 for a seven-day experiment.^[25] The prototype achieved 100% successful unrolling in microgravity, extending to 4.67 m in length and 1.67 m in width for an approximate area of 7.8 m², while generating about 2 kW of beginning-of-life power.^[5]^[13] On-orbit data confirmed effective vibration damping, with the primary structural mode observed at 0.41 Hz—20% lower than ground predictions but indicative of robust stability—and overall dynamics aligning closely with models after accounting for blanket tension variations.^[5] A core innovation validated during testing was the high-strain composite slit-tube booms, which harness stored elastic energy for autonomous, tension-controlled deployment, demonstrating scalability for high-power systems up to 20 kW per wing.^[5] Post-test analysis refined finite element models using flight data, identifying minor thermal performance tweaks such as enhanced blanket stiffness to mitigate uneven heating observed in vacuum simulations, which informed subsequent design evolutions.^[5]^[24] Following the 2017 demonstration, ROSA technology advanced through further qualification testing, leading to the integrated ROSA (iROSA) variants qualified between 2018 and 2021 for ISS upgrades. As of September 2025, Redwire (formerly DSS) was awarded a contract to provide ROSA solar arrays for Axiom Space's first commercial space station module, marking continued commercialization and adaptation for private space infrastructure.^[26]

ISS Applications

Initial ROSA Test Mission

The Roll-Out Solar Array (ROSA) flight experiment served as the first in-space demonstration of the technology, launched to the International Space Station (ISS) on June 3, 2017, aboard the SpaceX Falcon 9 CRS-11 commercial resupply mission.^[11] The payload was transported in the Dragon spacecraft's unpressurized trunk and subsequently transferred to the ISS for operations.^[2] On June 18, 2017, astronauts used the Canadarm2 robotic arm to position and deploy the array externally, attaching it via a Flight Releasable Attachment Mechanism (FRAM) for testing.^[2] The experiment was sponsored by NASA, in collaboration with the U.S. Air Force Research Laboratory (AFRL) and Deployable Space Systems (now part of Redwire Space).^[11] The ROSA unit featured a single flexible solar array wing measuring approximately 4.67 meters in length and 1.67 meters in width when deployed, designed to simulate photovoltaic performance with six active solar cell strings and mass simulators.^[5] Deployment relied on stored strain energy in composite slit-tube booms, unrolling the array without motors in a process captured by ISS external cameras, accelerometers sampling at 200 Hz, and photogrammetry targets for structural analysis.^[11] Over the course of the one-week test period from June 17 to 25, 2017, the array underwent evaluations of deployment dynamics, photovoltaic output via current-voltage sweeps, and environmental responses such as thermal cycling and orbital shadowing.^[27] Testing outcomes validated the array's performance in microgravity, with successful unrolling confirming low deployment loads and high damping in structural modes—though the first bending mode frequency was about 20% lower than ground predictions, providing valuable data for model refinements.^[5] Photovoltaic testing demonstrated effective power generation from the flexible blanket, with no major structural failures observed, despite minor unexpected edge flapping.^[11] Retraction attempts using a motor-driven lanyard partially succeeded but encountered issues, leading to the array's safe jettison from the robotic arm on June 26, 2017, without risk to the ISS or incoming vehicles.^[2] This mission proved the feasibility of roll-out architectures for scalable, lightweight solar power systems, directly informing the design and risk reduction for subsequent larger-scale implementations like the iROSA upgrades.^[1]

iROSA Upgrade Series

The iROSA (ISS Roll-Out Solar Array) upgrade series represents a significant enhancement to the International Space Station's power system, featuring high-efficiency, lightweight solar arrays designed to augment the aging rigid panel arrays. Each iROSA is a 20+ kW-class wing utilizing advanced roll-out technology for compact storage and reliable deployment in orbit. NASA procured six such units between 2020 and 2022, with manufacturing and delivery handled by Redwire in collaboration with Boeing's Spectrolab, which provides the 30.7% efficient XTJ Prime solar cells. These arrays are engineered to extend the ISS's operational life beyond 2030 by increasing overall power availability by up to 30%.^[28]^[6] The deployment series began in earnest following the foundational ROSA prototype test, with installations occurring via a series of spacewalks and robotic operations. The first pair, iROSA 2B/4B, arrived via SpaceX's CRS-22 mission in June 2021 and was attached to the P6 truss segment using the Canadarm2 robotic arm, followed by astronaut-led spacewalks for final positioning and unrolling on June 16 and 25, 2021.^[29] Subsequent pairs followed: iROSA 3A/4A launched on SpaceX CRS-26 in November 2022 and installed on the P4 truss on December 3 and 22, 2022; iROSA 1A/1B delivered by SpaceX CRS-28 in June 2023, mounted on the P6 truss on June 9 and 15, 2023. Each installation involves preparing modification kits on the existing truss structure during preparatory spacewalks, then robotically positioning the stowed arrays before crew members connect electrical harnesses and initiate deployment, a process that typically spans two extravehicular activities per unit.^[30]^[29] These upgrades augment rather than replace the original rigid solar arrays, with the roll-out wings positioned in front of the legacy panels to capture additional sunlight without shadowing issues. The six iROSAs collectively add 120 kW to the ISS's power capacity, enabling support for advanced experiments, increased crew capabilities, and future module integrations. Post-installation performance has been robust, with the arrays demonstrating over 98% operational efficiency in low Earth orbit, as measured by power output stability and minimal degradation during initial orbital operations. For instance, telemetry from the June 2023 CRS-28 mission confirmed stable output from the iROSA 1A/1B pair, averaging approximately 20 kW per wing under nominal conditions shortly after deployment.^[1] As of November 2025, the six installed iROSAs are operating nominally. A fourth pair (iROSA 2A/3B) was delivered in January 2025 and is scheduled for launch on a future commercial resupply mission in late 2025 or early 2026, with installation planned on the P4 and S6 trusses thereafter to complete augmentation of all eight power channels.^[31]

Beyond ISS Applications

Lunar Gateway Integration

In 2019, Redwire was awarded a contract by Maxar Technologies, the prime contractor for NASA's Power and Propulsion Element (PPE) of the Lunar Gateway, to develop two Roll-Out Solar Array (ROSA) wings capable of generating a total of 60 kW of power.^[32] These arrays build on the iROSA technology baseline proven on the International Space Station, but are scaled up for deep-space demands. Each wing measures approximately 18 meters by 10 meters when deployed, providing the high-power density needed to support the Gateway's solar electric propulsion systems and overall station operations.^[33] Key milestones in 2025 included the successful first full-scale deployment test of one ROSA wing in July at Redwire's facility in Goleta, California, demonstrating reliable motorless unfurling in a simulated space environment.^[33] The arrays are designed for the cislunar environment, incorporating radiation-hardened components and enhanced thermal protection to withstand the increased radiation and temperature extremes at lunar distances beyond low Earth orbit.^[34] Delivery of both wings to Maxar is scheduled for the fourth quarter of 2025, following additional qualification testing, to enable integration into the PPE ahead of its launch.^[35] The ROSA wings feature high-efficiency multi-junction solar cells, maintaining durability in the vacuum and radiation of cislunar space. Autonomous deployment mechanisms allow for crewless robotic installation on the Gateway, minimizing the need for extravehicular activity during assembly. In the planned Earth-Moon halo orbit, the arrays are expected to deliver up to 60 kW to power propulsion, habitats, and science payloads, supporting continuous station operations starting with the Artemis IV mission in 2028.^[36] This partnership between Redwire, Maxar, and Boeing underscores the evolution of ROSA for sustained lunar exploration infrastructure.^[33]

Other Spacecraft Missions

In addition to its applications on the International Space Station and the Lunar Gateway, the Roll-Out Solar Array (ROSA) technology developed by Redwire has been adapted for various commercial spacecraft missions, demonstrating its versatility across different orbital regimes and platform sizes. One notable example is the deployment of two 5 kW ROSA units on the Ovzon 3 communications satellite, a Maxar-built geosynchronous Earth orbit (GEO) spacecraft launched in January 2024. These arrays successfully unfurled in orbit and have operated nominally, providing reliable power generation in the harsh radiation environment of GEO while validating ROSA's performance for commercial telecommunications applications.^[37] Redwire has secured multiple commercial contracts for ROSA integrations between 2023 and 2025, expanding its use to non-governmental platforms. In July 2024, the company received a follow-on order from Thales Alenia Space to supply ROSA wings for the Space Inspire product line of telecommunications satellites, developed with support from the European Space Agency. This contract highlights ROSA's role in enabling power systems for innovative, maneuverable spacecraft in low Earth orbit (LEO). Furthermore, in September 2025, Redwire was awarded a contract by Axiom Space to provide ROSA-based solar arrays for the power module of the Axiom Station, the first commercial space station intended to succeed the ISS. These arrays are scaled to meet the station's energy demands, leveraging ROSA's compact stowage to facilitate launch efficiency on commercial vehicles.^[38]^[39] ROSA's design allows for scalable adaptations, including smaller configurations suitable for small satellites and hybrid systems that combine roll-out flexibility with rigid panel elements for enhanced structural support in diverse missions. For instance, the technology's modular architecture supports power outputs from 10 kW upward, making it adaptable for constellation deployments and secondary payloads where volume constraints are critical. In GEO simulations and real-world operations like Ovzon 3, ROSA has demonstrated power retention exceeding 90% over extended periods, attributed to its robust composite boom and flexible blanket materials that mitigate degradation from thermal cycling and radiation.^[10]^[37]

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[40]
Redwire Awarded Contract to Provide Roll-Out Solar Arrays for ...
Sep 25, 2025 · Redwire Awarded Contract to Provide Roll-Out Solar Arrays for Axiom Space's First Space Station Module. September 25, 2025 7:30am EDT Download ...