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How LeoStella uses software to track satellite hardware

TUKWILA, Wash. — LeoStella’s satellite factory has tons of hardware spread out over 22,000 square feet of space, but the secret ingredient for its manufacturing process may well be the software.

“What you see here is the physical layout,” Brian Rider, LeoStella’s chief technology officer, told us during a tour of the satellite venture’s headquarters in Tukwila, just south of Seattle. “But what’s a little bit harder to see is the digital process behind it.”

LeoStella, a joint venture co-owned by BlackSky Holdings and Thales Alenia Space, relies on a workflow management system that tracks satellite components all the way through design and manufacturing. Employees use a digital dashboard to make sure that every part is in its proper place at the proper time.

“It’s truly not just a paperless process, but it’s a digital, intelligent manufacturing approach,” Rider explained. “We can record all of our manufacturing details. We can do statistical process control and understand where we have areas where we can make our systems less restrictive, or more restrictive to improve product quality.”

The facility itself is designed to maximize efficiency for turning out up to 40 satellites per year, including two satellites per month for BlackSky’s Earth-observation constellation. The interior of a standard-issue building in a suburban business park was extensively remodeled when LeoStella took over the space in 2018.

“Not many companies have the chance to take a step back and start from a clean sheet of paper, and really think about all the aspects that make satellite production possible and efficient and affordable,” Rider said. “That’s what we did at LeoStella.”

By Alan Boyle

Mastermind of Cosmic Log, contributing editor at GeekWire, author of "The Case for Pluto: How a Little Planet Made a Big Difference," president of the Council for the Advancement of Science Writing. Check out "About Alan Boyle" for more fun facts.

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