Solar Panel Manufacturing Process Explained Step-by-Step

As the world becomes more conscious of the environmental impact of traditional energy sources, businesses are increasingly turning to solar power as a sustainable, clean and cost-effective solution for their energy needs.

The solar panel market has seen tremendous growth in recent years, with an increased variety of panel types and manufacturers now available to choose from.

In this article, we will explore the various types of solar panels, highlighting their differences. Additionally, we’ll delve into the solar panel manufacturing process, quality control, and certifications and standards. Furthermore, we’ll offer an overview of the solar panel market, covering demand trends, pricing, and competition.

Overview Of The Solar Panel Market

The exponential growth in solar adoption over the past decade has been driven largely by the declining costs of solar panels and the increasing demand for renewable energy sources.

Solar energy is now one of the most cost-effective sources of energy in many parts of the world, with prices continuing to decline. According to a report by the International Renewable Energy Agency, the cost of solar power decreased by 82% between 2010 and 2019.

In terms of competition, the solar panel market is highly fragmented, with a large number of manufacturers operating globally. However, a few companies dominate the market, including Canadian Solar, JinkoSolar, Trina Solar, and First Solar.

These companies account for a significant share of the global solar panel market, and their success is largely driven by their ability to produce high-quality solar panels at a low cost.

Types Of Solar Panels And Their Differences

There are three main types of solar panels: monocrystalline, polycrystalline, and thin film. Each of these types has its own unique characteristics and advantages PV manufacturers need to be aware of. 

Monocrystalline Solar Panels

Monocrystalline solar panels are made from a single crystal of silicon. The use of a single crystal makes them more efficient than other types of solar panels. In a single crystal, the electrons that generate the electric current flow more freely through the material, resulting in higher efficiency.

In contrast, other types of solar panels such as polycrystalline and thin-film panels are made from multiple crystals of silicon. This can result in boundaries between the crystals that impede the flow of electrons and reduce the efficiency of the panel.

In addition to their higher efficiency, monocrystalline solar panels also tend to have better performance in low-light conditions compared to other types of solar panels.

However, they are generally more expensive to produce. While temperature and shading can impact their output, advancements are improving their tolerance in these areas. The cost-effectiveness compared to other options depends on various factors like electricity prices, system size, and local incentives.

Polycrystalline Solar Panels

Polycrystalline solar panels, also known as multi-crystalline, are made by melting and merging multiple silicon crystals. This process results in a distinct speckled appearance and generally lower efficiency (around 5-10% less) compared to monocrystalline panels due to the presence of grain boundaries.

However, they are typically more affordable due to a simpler manufacturing process. Both manufacturing methods have environmental considerations, and responsible companies strive to minimize their impact.

Polycrystalline panels offer a balance between cost and performance and can be a suitable choice for many applications. They might even exhibit better performance in high-temperature environments compared to some monocrystalline options.

Thin-Film Solar Panels

Thin-film solar cells are produced by depositing thin layers of photovoltaic materials onto various substrates, allowing for lighter and potentially flexible panels.

They typically use less semiconductor material compared to crystalline silicon modules. Some thin-film materials like cadmium telluride (CdTe) and copper indium gallium selenide (CIGS) offer competitive efficiencies, while others like amorphous silicon (a-Si) have lower efficiencies.

The cost comparison between thin-film and silicon can be complex, and various factors like specific technologies and market conditions come into play.

It's important to note that some thin-film materials like CdTe raise environmental concerns due to potential toxicity, and responsible companies strive to address these issues through research and development.

Silicon Versus Thin Film

At present, the solar market consists of either silicon or thin-film. Silicon is by far the most dominant solar cell technology with at least 90 percent of solar panels being either monocrystalline or polycrystalline.

The biggest advantage silicon has over thin-film technologies is efficiency. Silicon solar panels have an efficiency of between 20 to 25% while thin film solar panels have a maximum efficiency of around 15%. Silicon cells are, however, more expensive to produce.

The biggest advantage of thin-film solar cells is they can be applied on almost any material. This makes it possible to produce solar panels with different characteristics such as lighter or flexible solar modules. As we’ve mentioned, however, thin-film solar panels are less efficient. This is the main reason why they are less popular than silicon.

Solar panel efficiency refers to the amount of sunlight that a solar panel can convert into usable electricity. The higher the efficiency, the more power the solar panel can produce.

Several factors affect solar panel efficiency, including cell design, materials, and environmental conditions. Material (silicon or thin-film) is by far the most important determinant of solar cell efficiency.

The Solar Panel Manufacturing Process  

The manufacturing process for solar PV panels typically involves several steps which include; wafer production, cell production, PV module production, and testing.

Wafer Production:

1. This step involves purifying silicon, usually from quartz sand.

2. The purified silicon is melted and grown into a cylindrical ingot using a process like the Czochralski process.

3. The ingot is then sliced into thin wafers using a diamond saw.

Cell Production:

1. The wafers are cleaned and etched to improve surface properties.

2. A phosphorous layer is diffused onto the front surface to create a positive-negative junction, which enables electricity generation.

3. Metal contacts are applied to the front and back of the cell to collect electricity.

4. An anti-reflective coating is applied to the front surface to minimize light reflection and maximize absorption.

Module Production:

1. Multiple solar cells are connected electrically in series and parallel to form a string.

2. The strings are encapsulated between a front sheet (typically glass) and a backsheet (usually polymer) to protect the cells from environmental factors.

3. A frame, usually made of aluminum or stainless steel, is added for structural support and mounting purposes.

4. A junction box is attached to the back of the module to house electrical connections.

Testing:

Completed modules undergo rigorous electrical and mechanical testing to ensure they meet performance and safety standards.

Quality Control In Solar Panel Manufacturing

Solar PV panels need to be produced to a high standard of quality. Quality control measures can include visual inspections, electrical testing, and performance testing. These measures help to identify potential defects or issues with the solar panels before they are shipped to customers.

Solar Panel Certifications And Standards  

There are several certifications and standards solar panel manufacturers need to obtain to demonstrate the quality and efficiency of their products. These certifications and standards can include UL certification, IEC certification, and the Energy Star label.

Obtaining these certifications and standards can help to build customer trust and increase the overall competitiveness of the manufacturer.

Conclusion  

Choosing the right solar panel is an important decision that requires careful consideration of the different types of solar panels, their efficiency, and the manufacturing process. By understanding the differences between monocrystalline, polycrystalline, and thin-film solar panels, manufacturers can make an informed decision that meets their goals.