Regher Solar: Powering the Future of Space Exploration

The Expanding Space Economy and the Demand for Affordable Solar Power

The fundamental calculations are straightforward. Considering the projected number of satellites slated for launch over the coming decade, the required quantity of solar panels, and current manufacturing capabilities, a significant gap emerges. There are a substantial number of satellites planned, a considerable demand for solar panels, and an insufficient supply to meet it. Regher Solar is positioning itself to address this challenge by aiming to reduce the cost of space-qualified solar panels by 90% while simultaneously increasing production by an order of magnitude.

This is an ambitious objective, but favorable scientific advancements and market trends provide the company with a beneficial momentum. The core challenge lies in achieving an optimal equilibrium between cost-effectiveness and performance, all while maintaining a relatively streamlined manufacturing process. Naturally, a simple solution would already be implemented if one existed.

Differences Between Terrestrial and Space-Grade Solar Cells

Solar cells designed for use on Earth differ considerably from those employed in space. On the ground, limitations regarding size and weight are minimal; cells can be larger, heavier, and less efficient – and significantly cheaper to produce.

Conversely, space-based solar cells necessitate high efficiency, minimal weight, and resilience against the harsh conditions of space, including radiation and temperature variations. This results in a premium product with a cost five to ten times greater, relying on small-scale processes and expensive materials.

Regher Solar’s Innovative Approach

Regher Solar has developed a space-grade solar cell that, while not matching the performance of dedicated space solar cells, approaches it closely – at a fraction of the cost and with the potential for large-scale production using existing methods. For a single, high-value geostationary satellite costing $200 million, the expense of top-tier panels is a minor consideration.

However, when deploying thousands of small satellites with limited lifespans, panel costs become a substantial portion of the overall budget. In such scenarios, a 20% reduction in performance may be an acceptable trade-off.

According to Stanislau Herasimenka, CEO and co-founder of Regher, their product isn’t based on a single breakthrough, but rather on a series of incremental improvements and a deep understanding of the evolving needs of the space economy.

“The technology has historically developed within a high-cost, low-volume framework,” he explained. “Space panels typically begin with expensive substrates like germanium or gallium arsenide, coupled with costly processing techniques. Expensive interconnects, glass, carbon fiber, or aluminum substrates, and manual assembly contribute to top performance and low degradation, but scalability is severely limited. Increasing production tenfold is simply not feasible with current methods.”

Meeting the Growing Demand

The number of satellites being launched is poised to double, triple, and eventually increase tenfold. Utilizing terrestrial cells is not viable due to their rapid failure in space, and established manufacturers of high-performance III-V cells cannot meet the anticipated demand. Therefore, Regher Solar has combined the best aspects of both approaches to create cells that are space-ready, affordable, and rapidly producible.

A Regher flexible silicon solar cell constructed with a 20-micron silicon substrate. Image Credits: Regher Solar

“Currently, we operate an R&D pilot line capable of producing small quantities of panels – 50 kilowatts, approximately 5% of the space industry’s current output,” Herasimenka stated. “However, our silicon-based design and packaging compatibility with automated production should enable us to scale to 10 megawatts, exceeding the entire space industry’s current capacity, within a year.”

The product is novel, but doesn’t rely on any unproven or exotic techniques, making such rapid scaling potentially achievable. Herasimenka outlined several modifications they implemented to attain space-like performance at terrestrial-like prices.

Key Technological Advancements

Firstly, they significantly reduced the thickness of the silicon substrate, paradoxically increasing its resistance to radiation by minimizing absorption. They also modified the impurities and doping process to enable low-temperature curing, allowing any resulting damage to be repaired through simple heating to 80 degrees Celsius. The coating, interconnect, and bonding materials are all space-stable. Furthermore, they minimized the non-active area surrounding the cells, maximizing the surface area dedicated to energy generation. The design also incorporates flexibility, as demonstrated in the images, to accommodate irregular shapes and enhance physical durability.

A lab technician demonstrates the flexibility of a Regher “solar blanket.” Image Credits: Regher Solar

Determining the optimal level of performance required careful consideration of the cost and planned lifespan of satellites within a given constellation. Surprisingly, excessive performance can be detrimental to constellation operators like Starlink. With thousands of satellites, economic viability is paramount – and there’s no benefit to exceeding performance or cost requirements if the plan is to replace them after five years. Prolonged functionality beyond that timeframe suggests potential cost savings elsewhere.

“Constellation designers plan for a specific duration in a particular orbit,” Herasimenka said. “Neither extremely short nor excessively long lifespans are desirable; most low Earth orbit satellites are designed for five to seven years. We tailored our design to meet this precise requirement. Degradation beyond that point is irrelevant to our customers.”

Funding and Future Prospects

Regher Solar’s entry into this emerging market was recognized with inclusion in Techstars’ 2019 batch, leading to discussions with manufacturers and preliminary agreements. They also secured a NASA SBIR Phase I award and an NSF Phase II grant, totaling $1.1 million. Armed with prototypes and initial funding, they generated $33 million in Letters of Intent (LOIs) over the summer and are currently finalizing an additional $50 million in commitments, according to Herasimenka.

Despite this promising outlook, the company must act swiftly to avoid being overtaken by competitors. “The landscape can shift dramatically within a few years, and by the time an industry recognizes the opportunity, it may be lost,” he said. Regher Solar is determined to capitalize on this opportunity and is currently seeking substantial investment to accelerate the development of their pilot line and, subsequently, full-scale manufacturing capabilities. They are preparing to launch a $5 million institutional equity seed round, expected to close by year-end, alongside $900,000 from individual investors.

With interest from established aerospace companies and endorsements from both NASA and the NSF, Regher appears well-positioned for success. The ultimate challenge – whether it lies in designing the innovative panel or actually scaling up production – remains to be seen.

(Updated to correct a minor inaccuracy in the penultimate paragraph regarding funding details.)