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According to a report by the United States Government Accountability Office, the space industry is on track to launch 58,000 satellites by the year 2030[1]. Some estimates are even higher. In this article, we’ll discuss the forces driving this growth and how selecting the right supplier can help satellite manufacturers maintain scalability in an increasingly competitive launch environment.
Along the way, we’ll examine four key obstacles that often hinder progress:
On October 4, 1957, the Soviet Union launched the world’s first man-made satellite: Sputnik[2]. Though Sputnik itself carried no scientific instruments, its successful launch inspired a technological revolution. Just three months later, the United States launched Explorer 1 into space, marking the beginning of American space exploration as we know it today.
In the nearly seventy years since Sputnik, satellites have rapidly evolved from simple radio transmitters to sophisticated technology supporting a wide range of critical functions.
Modern satellites have dramatically expanded our access to space, enabling constellations of small satellites and real-time global data services. Today, the most common uses include global communications such as satellite internet and military SATCOM. These services are now enhanced by integrated, multi-orbit satellite networks that offer greater resilience, reach, and flexibility. Earth observation is another major application for modern satellites, supporting climate monitoring, disaster response, and agriculture through increasingly high resolution imaging[3]. Additionally, navigation and timing systems like GPS remain foundational for transportation and defense.
The satellite economy is in full swing.
The global satellite market is expected to grow sevenfold in the coming years, driven by the proliferation of small satellites, mega-constellations, government initiatives, and commercial space ventures[4].
Major players from private space companies are some of the heaviest drivers of new demand. Nearly two-thirds of SpaceX’s orbital launches last year were devoted to expanding its Starlink broadband constellation, now the largest satellite network ever assembled with over 7,600 active satellites. SpaceX is aiming for a staggering 170 orbital launches in 2025 – out of 64 missions this year, 48 have been Starlink flights[5]. Amazon’s Project Kuiper recently launched 27 satellites into low earth orbit – with plans to deploy over 3,000 satellites in the future in order to provide global internet coverage. Existing and emerging satellite providers continue to innovate and expand advancements across the space ecosystem[6]. Increased demand is also motivated by government satellite constellations like Europe’s IRIS2 and the U.S. Space Force’s Proliferated Warfighter Space Architecture[7].
Rapid growth is largely fueled by the increased popularity of services provided by satellites in low Earth orbit (LEO), an orbital location approximately 1,200 miles or less above the Earth’s surface. LEO is a central catalyst to the satellite boom because it supports lower launch costs, faster data transmission via low latency satellites, and is the preferred zone for mega-constellations[8]. Demand is further driven by the large number of satellites required to maintain continuous coverage of the Earth from the low altitudes of LEO.
New breakthroughs in the satellite sector are driving the future of scientific and space exploration.
A 2023 Deloitte study confirmed that “advances in technology, increased private sector investment, and rising demand for space data are reshaping the space sector.” [9]
Reusable heavy-lift launch vehicles – such as SpaceX’s Falcon 9 and Starship or Blue Origin’s New Glenn – help to drastically reduce costs and increase launch cadence and scale. Miniaturized SmallSats and CubeSats promote faster development cycles and easier deployment in large constellations. Software-defined satellites can be reprogrammed after launch to change various payload specifications like beams, coverage areas, bandwidth, power levels, or frequencies[10].
As the number of satellite constellations in orbit grows, the pressure is on manufacturers to deliver innovative systems at scale. Even a minor delay or defect can cascade into major project setbacks. Launch schedules are tightly coordinated, and a single missed delivery can delay an entire mission – sometimes by months or even years. Partnering with the right supplier is key to staying competitive in a rapidly evolving launch market.
Reaching 58,000 satellites by 2030 requires more than ambition. By partnering with suppliers who bring reliable, space-proven components, engineering expertise, and robust manufacturing capabilities, you can build a scalable supply chain that’s as resilient and forward-looking as your mission.
Supply chain disruptions have become a defining challenge in the New Space market, where lead times and inventory availability can make or break a scheduled launch. To dramatically increase the number of satellites in orbit by 2030, manufacturers need a reliable approach to sourcing that helps safeguard against any potential disruption in the supply chain – from raw material shortages to unforeseen geopolitical delays. To prevent a single component from derailing an entire program, it’s important to anticipate and account for lead times, diversify material and component sources, and build redundancy into your supply chain[11]. Suppliers with robust inventories, strong logistical capabilities, and transparent business continuity and communication plans can help you to mitigate risk overall. Strong supplier partnerships allow manufacturers to stay agile amid shifting demands and keep launch schedules on course.
Increasing the number of satellites in orbit depends not just on production speed, but on how well manufacturers can scale without compromising on quality.
Satellite manufacturers need to know that components used in their satellite are going to work every time, without dramatic changes in performance. Stringent quality management and testing procedures help ensure each satellite is built to meet mission requirements and perform reliably in space[12]. These processes allow manufacturers to identify problems early on and minimize the risk of failure.
Trusted component suppliers offer pre-qualified, flight-proven components that reduce the need for redundant testing and help you to accelerate integration to reliably meet mission timelines. The right supplier will be able to provide you with full traceability and qualification/testing data that every part has been properly documented, tested, and verified to vigorous performance specifications. By partnering with suppliers who maintain low defect rates and adhere to aerospace quality standards, manufacturers can ramp up production with confidence.
From prototype to production, modern satellites often require a mix of commercial off-the-shelf (COTS) components and custom-designed solutions. This can result in unique challenges to the success of large scale launches.
When designing satellite systems, time is at a premium for busy engineers who need to iterate quickly and may not have the bandwidth to focus on component-level problems. The right suppliers can offer expert engineering support from initial product selection to implementation. Choosing a supplier that has the ability to modify standard components to your mission-specific needs – and a deep catalog of field-proven products compatible with the fluids used in space – can help you significantly reduce design headaches and prepare for next-generation updates.
To grow the number of satellites in the sky, satellite manufacturers must consider the impact of production capacity. New LEO mega-constellations can consist of hundreds or even thousands of satellites – and require numerous launches[13]. To stay viable, you can’t fall behind. Whether you need a prototype or are designing for a mega-constellation, it is important to consider how your production goals may change overtime. The right manufacturing partner can provide you with the support and flexibility you need to meet evolving technical and production requirements. Collaborating with a component supplier that can scale production to match your volume needs can help you keep up with demand, reduce pressure on internal manufacturing teams, and mitigate risk throughout every phase of your mission. Automated manufacturing practices can further speed up lead times to allow you to ramp up production efficiently while maintaining consistency and quality across large satellite constellations.
At The Lee Company, we make it our mission to solve the toughest fluid control problems in space and beyond. Whether you’re an industry mainstay or New Space start-up, we’re ready when you are. We bring the parts (and people) you need to power tomorrow’s technology.
Built for space and trusted by engineers, our solutions are fueled by our deep heritage in space and over 75 years of engineering expertise. We’ve delivered more than 500,000 certified parts that have supported a wide range of space missions. It’s likely that we already have the precise flow control solution you need. If not, our engineers can modify our COTS components to meet your specific mission requirements without significantly increasing costs or lead times.
Standard Lee parts are designed for the cycles needed for a successful mission – whether thousands or millions. Our components are made in the U.S. and export-ready, backed by proven licensing support for ITAR, EAR, and global compliance. Each part is 100% functionally tested under a rigorous aerospace quality management system (AS9100) to guarantee performance throughout the life of the system it is installed in. We follow a stringent product development and revalidation testing protocol, which helps our spaceflight customers eliminate risk when failure is not an option.
Lee engineers specialize in working with customers on an engineer-to-engineer level to solve complex fluid control problems. Our global presence allows us to provide local and accessible technical support to our customers, streamlining product development and innovation. If you are looking for a fluid control supplier for your satellite design or other New Space application and would like to learn more about products offered by The Lee Company, contact a Lee Sales Engineer today.
Sources:
Always verify flow calculations by experiment.
*There are many parameters to consider when determining V-Factor. Click here for more information.
