A ViaSat-3 satellite journey: from factory to space
04-17-2026
8-minute read
By David Abrahamian, Vice President, Space Systems
The path to commercial service of a ViaSat-3 (VS-3) satellite is a huge endeavor. It involves a series of intricate steps and procedures that transform individual components into an incredibly powerful ultra-high-capacity, highly flexible communication satellite.
Assembly, Integration & Testing (AI&T)
Before a VS-3 spacecraft is ready to provide service from geostationary Earth orbit (GEO), it begins as thousands of components and modules which are assembled into over 40 units of payload hardware, all painstakingly put together in Viasat’s Tempe, Arizona facility. Once all of the payload units are assembled and tested at the unit level, they are integrated into the payload module, which following the first round of integrated payload testing, is then shipped to Boeing’s facility in El Segundo, California.
From there, Viasat and Boeing work together to mate the VS-3 payload module to the bus module of Boeing’s powerful 702MP+ satellite platform, which is the main body component and structure of the spacecraft. This platform or ‘bus’ performs all of the “housekeeping” in support of the payload, including providing the structure, power, thermal control, navigation and altitude control, as well as providing telemetry back to the ground to keep the ground informed as to how everything is performing in space.
Once the bus and payload are mated, the combined modules start to look like a spacecraft.
ViaSat-3 F3 in the Boeing factory in El Segundo, CA
Satellite testing
Throughout the AI&T process, Viasat and Boeing engineers put the satellite and its components through an exhaustive battery of tests designed to push the units, subsystems and overall spacecraft to its limits to ensure it performs in accordance with its specifications and will meet its reliability requirements. Our underlying philosophy in designing a test program is to “test as you fly” as much as is practical given the constraints of working in a 1g environment (normal Earth gravity) and not being able to fully deploy the spacecraft in its flight configuration in a vacuum chamber.
We test the spacecraft in conditions that attempt to simulate or mimic everything that the spacecraft will experience throughout its lifetime starting with the loud and often violent launch to the harsh environment of space. We refer to this gauntlet of testing as “shake ‘n bake,” because we shake the satellite to simulate launch and bake (as well as freeze) it in a vacuum chamber to simulate the relentless cycles of hot and cold that it will see on orbit. Throughout this, we will verify that each system is operating flawlessly with engineers from Viasat and Boeing meticulously checking and validating each and every detail.
Thermal vacuum testing
Inside a giant vacuum chamber, the satellite is subjected to the extreme temperature fluctuations it will encounter in space, which can swing from a blistering 248° F (120° C) in direct sunlight to freezing conditions of minus 374° F (-190°C) in the shadow of the earth. To simulate this environment, the inner walls of the chamber are cooled with both liquid and gaseous nitrogen and warmed with specialized heating systems, all while maintaining a vacuum. Thermal vacuum chamber testing is the “bake” (and freeze) part of the “shake n bake” testing.
Vibration testing
The “shake” part of “shake ‘n bake” comes through vibration testing, where we will shake the satellite in all three axes to simulate the violent environment of launch. Launch is the harshest mechanical environment that the spacecraft will experience, as the rocket accelerates the spacecraft from the surface of the earth, overcoming gravity to reach earth orbit. Astronauts and satellites will experience 3-6 g's during launch (g-force), so, we will test our satellites to simulate this environment. With accelerations like this, an astronaut or the spacecraft will feel up to six times their normal weight while being vigorously shaken! Vibration testing ensures that the spacecraft's structural design can survive the harsh demands of the launch environment without breaking and most importantly, will still function as we expect once it reaches orbit.
Acoustic testing
Acoustic testing can simulate the higher frequency vibrations that the spacecraft will see during launch that cannot be replicated during vibration testing. In a specialized acoustic chamber, powerful speakers recreate the intense higher-frequency acoustic environment of a rocket launch, validating that every component and connection remains fully functional, even at an eardrum shattering 140 decibels.
Deployments
Following the mechanical environmental testing (vibration and acoustics), we will simulate the on-orbit deployment of solar arrays, reflectors, radiators and thrusters. By performing these tests after mechanical environments, we can validate that all of the mechanisms and pyrotechnic devices that trigger the deployments can survive the simulated launch. Because the structures that we’re deploying are not designed to support their own weight in a 1g environment, we will have to provide them with some additional support to simulate a zero-g space environment.
In the case of the solar arrays, this requires using large gravity offloading fixtures that will essentially hang the solar arrays from the ceiling while firing pyrotechnic restraints that hold the solar arrays to the north and south walls of the spacecraft. Reflectors and radiators will be offloaded by using giant helium balloons to simulate zero-g while once again, pyros are fired to initiate the deployment sequences.
ViaSat-3 F3 north wing deployment test
Electromagnetic compatibility (EMC) testing
This verifies that all electronic systems coexist harmoniously, with no interference or crosstalk between subsystems, and that the satellite can similarly tolerate the presence of external RF energy, such as that from radars and launch vehicle telemetry systems in use during launch.
Payload testing
This is a comprehensive suite of tests that measures payload radio frequency (RF) performance, which is repeated at various stages of the integration and test process. We will first perform a reference set of tests in our Tempe facility once the payload integration is completed. This first test establishes a baseline against which we’ll compare results of the same suite of tests during thermal vacuum testing, again during the post-mechanical testing phase, called Final Integrated System Test (FIST) just before the satellite is shipped to the launch site, and again during In-Orbit Testing (IOT).
Transport to launch site
Once all testing milestones have been successfully completed, the satellite embarks on the next stage of its journey: traveling from the Boing facility in El Segundo, CA to Cape Canaveral, FL either by ground or by air.
For VS-3 F1 and F2, we chose to fly the spacecraft to meet launch schedules and in both cases, used one of the world's largest cargo aircraft, the Antonov An-124. The satellite’s shipping container design was tailored to the shape and dimensions of the An-124's cargo bay and is the only commercial aircraft that the satellite’s shipping container will fit into.
VS-3 F3 travelled to the launch site by road in the same shipping container on an extra wide truck – a journey that takes approximately 9-10 days to go coast to coast.
The sophisticated, climate-controlled shipping container maintains precise environmental conditions throughout the journey and protects the satellite against any damage that could happen during its journey.
ViaSat-3 Flight 3 leaving Boeing's El Segundo facility on its way to Florida's Space Coast.
The loading and unloading processes, each requiring 4-6 hours, follow carefully choreographed procedures that ensure the satellite arrives in pristine condition. Upon arrival at the launch site, the spacecraft container is taken to a Payload Processing Facility (PPF).
Pre-launch operations
From here, the satellite is carefully unpacked, marking the beginning of the final preparations for launch.
The first phase of the launch campaign involves basic testing of the spacecraft, once again, to ensure that nothing has changed or broken during shipping. This standalone testing includes a visual/physical inspection of the spacecraft, powering up all spacecraft systems to confirm that they’re alive, and running a suite of specialized tests to ensure that everything is healthy.
Once standalone testing is completed, the spacecraft is lifted and mated to its payload adapter and the separation system is installed. This marks the beginning of combined operations, where the spacecraft and launch vehicle operations are tightly coordinated and integrated. At this point, we will verify that we can command the satellite and charge batteries through the umbilical harness on the payload adapter which will eventually be mated to the rocket’s umbilical for flight.
Finally, we will remove all remaining protective covers, perform final cleaning of surfaces and perform a final inspection of all features and structure and collect meticulous photo documentation. The spacecraft is now ready for encapsulation in the payload fairing (i.e., the rocket’s nose cone), which protects the spacecraft both on the ground and ascent through the atmosphere during launch. Depending on the specific rocket being used, the encapsulated spacecraft will be transported anywhere from a few days to a week before launching out to the rocket and will be mated to the rocket. Following completion of the mating, we will once again power up the spacecraft and perform a suite of testing to confirm that we can command the spacecraft, receive telemetry and charge batteries through the rocket’s umbilical harness.
Launch day
Approximately eight hours before the opening of the launch window, our team heads to the launch control center and powers up the satellite and performs final system checks, confirming health and configuring all systems for flight. In the final few minutes before launch, the Flight Director will conduct a final flight readiness poll, confirming with each responsible party that their systems are ready: vehicle systems, propulsion, flight control, ground systems, range support, and flight safety.
Hundreds of specialists contribute to this coordinated effort, from meteorologists providing real-time weather analysis to range safety officers ensuring the launch corridor is clear and all safety requirements have been satisfied. Toward the end of the countdown, the Launch Conductor receives the final "go" from the team, followed by those defining words: "Go for launch"!
The launch vehicle then lifts off with the satellite to its next milestone: geosynchronous transfer orbit (GTO).
Post-launch operations
Approximately five hours after launch, the rocket releases the satellite into GTO, marking the beginning of the Early Orbit Phase. During this critical period, engineers on the ground assess the satellite’s primary systems and make sure it’s ready to head towards its final GEO orbital slot.
All the steps from launch to commercial services entry
Stage 1-3: First telemetry signals are acquired to confirm satellite’s health and then we begin to configure the satellite for initial deployments and preparation to start orbit raising.
Stage 4: Solar arrays deploy, providing electrical power.
Stage 5: One radiator deploys, providing the needed dissipation capacity for all the heat generated by various spacecraft components during orbit raising.
Stage 6: Ranging is performed using ground stations to improve knowledge and resolution of the spacecraft’s orbit so that we can update the orbit raising plan to be as efficient and accurate as possible in executing the thruster burns that will propel the spacecraft to GEO.
Stage 7: Over the next few months, the satellite will travel to its GEO position 22,000 miles above Earth via its all-electric propulsion system.
Stage 8: On-station operations: Once the VS-3 satellite arrives in geostationary orbit, we’ll begin a complex sequence to deploy its reflectors over the coming weeks, under continuous monitoring and evaluation by ground controllers. Finally, we will complete deployments with the deployment of its north radiator.
Stage 9: In Orbit Testing (IOT):
- Payload IOT: A repeat of the payload testing performed multiple times on the ground. This will confirm that payload performance has not changed or degraded as a result of launch and orbit raising. Results obtained through Payload IOT will be compared with results from reference performance testing, thermal vacuum and FIST.
- Bus IOT: Similar to Payload IOT, all bus systems are put through their paces to confirm that they remain healthy following launch and orbit raising.
- Antenna pattern mapping: Precise maps of the satellite's antenna performance are created by pitching and rolling the spacecraft to sweep RF energy over ground stations in both transmit and receive modes. This creates a detailed “map” of the antenna performance. Like Payload IOT, this will confirm that the antenna subsystem survived launch and orbit raising and performs consistently with testing on the ground.
- Satellite handover: Once all tests are complete and satellite performance is understood, the spacecraft manufacturer, Boeing will pass control of the VS-3 satellite to Viasat’s Satellite Control Centers. This marks the completion of the satellite design and manufacturing program.
Stage 10: Following VS-3 satellite hand-over to Viasat’s Satellite Control Center, final network integration and combined testing with our ground infrastructure takes place.
Following this process, the satellite is then ready to enter commercial service!
Delivering value: Commercial service
Once in service, it is anticipated that the satellite will provide in excess of 1Tbps throughput capacity and along with it the transformational potential to deliver substantial value across our business:
- Commercial aviation: The VS-3 constellation is expected to expand and enhance our Viasat AMARA in-flight connectivity solution, helping airlines deliver next-level experiences that improve the passenger experience and drive new lines of revenue.
- Business aviation: it is expected to further elevate our JetXP solution for an even greater standard of seamless, high-performance connectivity from takeoff to touchdown.
- Maritime customers: VS-3 offers a clear upgrade path for our maritime customers as part of NexusWave's fully managed bonded connectivity service. This next-generation ultra-high-capacity, high-speed service is designed to significantly enhance the 'office-like' and 'home-like' internet experience onboard vessels.
- Government and Defense: VS-3 is the next generation of commercial SATCOM reimagined for modern mission advantage, delivering high-throughput, flexible satellite connectivity that can help exceed performance, security, and resiliency requirements for our government partners across land, sea, air, and space.
- Home and Business Internet: The VS-3 constellation will help deliver fast, reliable internet to more homes and small businesses in rural communities around the world.
Each ViaSat-3 satellite represents the culmination of years and thousands, if not millions of hours of rigorous engineering, comprehensive validation, and operational excellence – with the aim of delivering reliable, high-capacity connectivity from 22,000 miles above Earth for Viasat customers around the world.
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