Lessons Learned

Michael Carter- Boulder, Colorado- December 27th, 2024.

At a Solstice party in Boulder, Colorado, I struck up a conversation with a retired Ball Aerospace (now BAE Systems) electrical engineer. I thought it was a rare and exciting opportunity as conversations with people like this can be a goldmine of insights. I was eager to learn about the evolution of satellite technology, its impact on telecommunications and the space launch industry, and glean some “lessons learned” from someone deeply experienced in the technical and operational aspects of aerospace.

As a product innovator and strategist in the power and energy sector, I love to explore developments in other industries to uncover potential applications to my own. This conversation gave me deeper insight into how satellite technology is rapidly evolving, addressing challenges like product obsolescence, shifting client needs, and futureproofing. It also gave me valuable insights into workflow, workload, and work structure in response to industry changes.

The Evolution of Satellite and Rocket Technology

Originally, satellites were designed for geostationary orbit, transmitting data indefinitely. Today’s satellites often de-orbit after their missions, burning up in the atmosphere or splashing down in the ocean to free up space for new vehicles. Rockets, too, have become smaller, adaptable, and reusable, tailored for varying payloads and mission requirements. These changes have reduced costs and increased the frequency of launches, making space more accessible.

The advent of miniaturized satellites—micro-sats, cube-sats, and nano-sats—has revolutionized the industry. Cube-sats can be as small as 10 cm (3.9 inches) in a single unit (1U), or stackable into 2U and 3U, or larger formats. These satellites, weighing less than 500 kg, operate in constellations—clusters of thousands of satellites performing coordinated missions in low Earth orbit (LEO).?

LEO constellations, typically at altitudes of 400–500 km, contrast sharply with the 30,000–40,000 km orbits of traditional geostationary satellites. This shift has transformed satellite communications by reducing latency, enabling rapid deployment, and lowering costs. For instance, Starlink has launched over 4,700 satellites and plans to deploy 4,500 more. China’s Guo Wang is preparing to launch a 13,000-satellite constellation, underscoring the global competition in this “new space race.” Scientific organizations are adapting as well. NASA, for example, has adjusted its 2025 budget request to include more LEO presence, reflecting the growing importance of smaller, distributed satellite systems (NASA?FY?2025 Budget).

These developments mirror disruptions in other industries and are reshaping the industry. Just as distributed solar power plants upended centralized thermal power generation, micro-sats and nano-sats are redefining satellite technology, enabling faster, cheaper, and more agile missions.

Adapting to Change

Companies like Ball Aerospace have had to pivot from designing large spacecraft to manufacturing smaller satellites based on third-party specifications. This shift brought significant challenges:

1. Workflow: The transition to client-driven projects increased reliance on email communication, leading to inefficiencies. Previously, engineers could resolve issues through quick in-person discussions. The switch to email as the primary mode of communication created bottlenecks, referred to internally as “Email Bankruptcy,” where overloaded inboxes hindered productivity.
2. Workload: Delays in communication extended project timelines, raising costs. To meet deadlines, management initiated crash programs, either reducing project scope or adding resources. However, engineers often chose to work longer hours rather than train new hires, compounding inefficiencies and stress.
3. Work Structure: The new client-driven approach fragmented projects into multiple, complex components requiring integration. This increased the need for coordination among teams, complicating workflows and slowing production.

How might we... Addressing the Lessons Learned?

From these challenges, several strategies emerge that can improve workflows and processes to improve efficiency. These include:

• Streamlined Communication: Adopting tools like Slack or Teams and defining clear communication protocols, like Stand-up meetings can reduce email overload and improve response times.
• Enhanced Training Programs: Investing in onboarding processes ensures new hires contribute quickly without overburdening current staff.
• Simplified Processes: Breaking down complex systems into modular components improves integration and reduces delays.
• Aligned Incentive Structures: Revising performance metrics to reward team collaboration over individual effort encourages knowledge sharing and collective success.

The aerospace industry’s adaptation to rapid change underscores the importance of agility, streamlined processes, and proactive problem-solving. These lessons are not just confined to aerospace; they resonate across industries navigating the challenges of technological evolution.

Michael Carter is principal of Energy Business Strategy Ltd, energy strategy advisors and consultants to the energy and electric power industry and may be reached at [email protected]

There is fascinating information on the nano-sat launch space and constellations complied by NewSpace. https://www.newspace.im