The integration of photovoltaic (PV) cells into aviation isn’t just a futuristic concept—it’s actively reshaping how aircraft operate, from small drones to experimental manned planes. Let’s dive into the nuts and bolts of how solar energy is taking flight.
One of the most groundbreaking applications is in high-altitude, long-endurance (HALE) unmanned aerial vehicles (UAVs). These solar-powered drones, like Airbus’ Zephyr, leverage ultra-thin, flexible PV cells laminated onto their wings. These cells generate enough power during daylight to keep the aircraft aloft for months, even at altitudes above 60,000 feet. The trick? Using gallium arsenide-based cells that achieve efficiencies over 30%, far surpassing traditional silicon panels. This allows the Zephyr to carry comms payloads for military or disaster-relief operations without needing to land for refueling.
But it’s not just about drones. Manned solar aircraft have achieved historic milestones. The Solar Impulse 2, for instance, completed a 26,000-mile circumnavigation in 2016 using 17,248 PV cells spread across its 236-foot wingspan. While not commercially viable yet, the project proved that intelligent energy management—storing excess solar power in lithium polymer batteries for night flying—could sustain flight without fossil fuels.
Aerospace engineers are now testing hybrid systems where PV cells complement traditional propulsion. Boeing’s subsidiary Aurora Flight Sciences developed a concept plane with solar panels covering 60% of its surface, reducing fuel burn by 10-15% during daylight hours. Even commercial aviation is dabbling—Air New Zealand recently trialed flexible solar films on cargo plane fuselages to power auxiliary systems, cutting APU generator use by 40%.
Satellites have been the OG users of space-grade PV tech. Modern communication satellites like SpaceX’s Starlink models use triple-junction cells that convert 34% of sunlight into electricity even in Earth’s radiation belt. What’s wild? These cells operate at 80°C in the vacuum of space while resisting degradation from cosmic rays—a far cry from your rooftop panels.
The real game-changer might be in electric vertical takeoff and landing (eVTOL) vehicles. Startups like Joby Aviation are experimenting with photovoltaic cells integrated into wing surfaces to extend urban air taxi range. By pairing 400 Wh/kg batteries with 24%-efficient perovskite-silicon tandem cells, prototypes show 15% range boosts—critical for making urban air mobility economically feasible.
Material science breakthroughs are driving these applications. Thin-film technologies like CIGS (copper indium gallium selenide) allow PV integration into curved aircraft surfaces without adding weight penalty—a must when every gram affects flight dynamics. NASA’s Helios Prototype achieved 96,863 feet altitude using 62,000 CIGS cells that weighed just 0.5 kg/m².
Challenges remain, of course. Cloud cover, airframe vibrations, and temperature extremes demand PV systems that outperform terrestrial installations. Researchers at MIT are developing “solar skins”—multilayer PV coatings that maintain efficiency even when partially shaded or heated to 150°F during supersonic flight.
Regulatory bodies are catching up. The FAA recently updated AC 43.13-2B to include standards for certifying PV systems on experimental aircraft, requiring rigorous testing for delamination risks at 400 knots airspeeds. Meanwhile, EASA’s new SC-VTOL-01 guidance mandates that solar-assisted eVTOLs demonstrate 30 minutes of emergency power solely from PV reserves.
Looking ahead, the combination of perovskite PV cells (now hitting 33.7% efficiency in labs) and advanced energy storage could enable truly carbon-neutral regional flights. Imagine a 50-seat hybrid-electric plane using wing-integrated solar cells providing 20% of cruise power—such concepts are already in wind tunnel testing at Airbus’ Hamburg R&D center.
From powering in-flight sensors to enabling year-long atmospheric research missions, photovoltaic technology is becoming aviation’s silent copilot. As cell efficiencies approach theoretical limits and aviation-grade PV costs drop below $0.30/watt, the sky isn’t the limit—it’s the power source.