With solar panel shipments accelerating at a phenomenal rate (with a 10% increase from 2021 to 2022), manufacturing has also increased to keep u with demand.  

If you are among the many people choosing solar, then you probably want to know where your unit is coming from and how it’s made just like anything else you purchase.

Ensure your unit is produced ethically and with the environment in mind by understanding how are solar panels made. 

At Rising Sun Solar Solutions, we understand that an informed choice is a powerful one, so we’re breaking down everything you need to know about solar panel manufacturing, from the materials involved to the rigorous testing process that ensures each panel meets quality standards. Let’s dive into the journey of how solar panels come to life.

What Are Solar Panels Made Of?

Solar panels are built from materials that optimize their ability to capture sunlight and convert it into usable electricity. At the core of a solar panel is silicon, a semiconductor material capable of converting sunlight into electricity through a process called the photovoltaic (PV) effect. Silicon is a primary component in most solar panels, usually in the form of monocrystalline or polycrystalline cells, each with distinct benefits and efficiencies.

Here is a breakdown of PV cells and the other components required to manufacture solar panels:

  • Silicon Wafers: Silicon is purified and crystallized to form wafers, which are then sliced into thin pieces and treated to form solar cells. Monocrystalline silicon panels are highly efficient and offer excellent performance even in low-light conditions. Polycrystalline panels, while slightly less efficient, are cost-effective and commonly used in residential installations.
  • Glass: A durable layer of glass is placed on the front of the solar panel to protect the silicon cells from environmental factors like rain, wind, and hail while allowing sunlight to pass through.
  • Aluminum Frame: The frame holds the glass and cells together, providing structural support and ease of installation.
  • EVA (Ethylene Vinyl Acetate) and Backsheet: These protective layers ensure that the solar cells stay encapsulated and shielded from moisture and air, maintaining the panel’s longevity and performance.
  • Conductive Metals: Thin conductive metal lines, typically silver or copper, run through the cells and carry the electricity generated within the panel.

All of these materials come together to make the solar panel that will go on your home or commercial building. 

Where Are Solar Panels Made?

Solar panels are manufactured worldwide, with key production hubs in countries like China, the United States, Germany, and Malaysia. China dominates global production due to its large investments in manufacturing infrastructure and access to raw materials. Many well-known solar panel brands also have manufacturing facilities across multiple countries to serve regional markets more effectively.

While different regions specialize in particular stages of the manufacturing process, solar panels undergo strict international standards to ensure they meet performance and safety benchmarks. As a family-run, local solar panel installer, we work with trusted solar panel suppliers who uphold the highest quality standards regardless of their production location, ensuring every panel we install is built to last and perform.

How are Solar Panels Made: Step-By-Step Process

The manufacturing of solar panels is a multi-stage process that requires precision and attention to detail. Let’s take a closer look at each stage:

1. Purification and Crystallization of Silicon: Raw silicon, extracted from quartz, undergoes a purification process to create high-purity silicon. This purified silicon is then melted and crystallized into large ingots, which are either monocrystalline (single crystal) or polycrystalline (multiple crystals).

2. Wafer Creation: The silicon ingots are sliced into thin wafers, each about the thickness of a sheet of paper. These wafers are then polished to remove any surface imperfections that could affect efficiency.

3. Cell Processing: The silicon wafers are treated with chemicals to create a positive-negative (p-n) junction, enabling them to convert sunlight into electricity. An anti-reflective coating is then applied to enhance light absorption.

4. Solar Cell Assembly: Multiple cells are connected using metal conductors, forming an interconnected grid that allows electricity to flow between the cells.

5. Lamination and Layering: The cell assembly is encapsulated between layers of EVA and glass and then laminated to ensure durability. The panel is sealed with a backsheet, providing additional protection from environmental exposure.

6. Framing: The laminated solar cells are framed with aluminum, which adds structural integrity and enables easy installation on rooftops and mounting systems.

7. Wiring and Junction Box: Finally, a junction box is added to the panel, containing all the necessary wiring connections for easy integration into the electrical system.

Each of these stages is carefully monitored to ensure the highest standards of quality, allowing solar panels to function optimally for decades.

Quality Testing of Solar Panels

Solar panels are subjected to various tests to ensure they meet quality, efficiency, and durability standards. At Rising Sun Solar Solutions, we prioritize installing panels that pass stringent quality checks to guarantee long-lasting performance and safety. Here are the main tests conducted on solar panels:

  • Thermal Cycling and Humidity-Freezing Tests: These tests simulate the extreme temperature changes and moisture levels solar panels may encounter. Panels must endure hundreds of cycles to demonstrate their resilience against thermal stress and humidity.
  • UV Exposure Tests: Solar panels are exposed to ultraviolet light to assess their durability under continuous sunlight exposure. This test ensures the panel materials won’t degrade prematurely due to UV radiation.
  • Mechanical Load Testing: Panels undergo pressure tests to simulate conditions like high winds, heavy snow, and other environmental loads. Mechanical load testing confirms the panel’s durability in various weather conditions.
  • Electroluminescence Testing: This test reveals any microcracks or defects in the solar cells that may not be visible to the naked eye. It ensures the panel is free of damage that could impact its long-term efficiency.
  • Performance and Efficiency Testing: Panels are tested under controlled light and temperature conditions to verify their power output and efficiency ratings, helping to ensure consistent energy production.

Every panel Rising Sun Solar Solutions installs undergoes rigorous testing to ensure optimal performance for our customers, so you can have confidence in your solar investment.

Partner with Rising Sun Solar Solutions Today!

Solar panels are an incredible investment, made to last and perform reliably through years of changing weather and environmental conditions. By understanding the materials, manufacturing processes, and quality testing that go into creating each panel, you can feel confident that you’re making a choice that benefits both your wallet and the planet.

At Rising Sun Solar Solutions, we’re dedicated to bringing solar power to homes and businesses in the most efficient, reliable way possible. Ready to experience the benefits of clean, renewable energy? Contact us today to get a free estimate and take the first step towards a brighter, more sustainable future.