2023/7/12 10:28 How are Solar Panels Made?

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GreenMatch / Blog / How are Solar Panels Made?

Text size Last updated: 13 April 2023

How Are Solar Panels Produced?

A solar PV module consists of solar cells, glass, EVA, backsheet and frame. Learn more about
the components and the process of manufacturing a solar panel.

Solar panels are a complicated piece of technology that requires a qualified engineer for
installation. If you’re interested in harnessing the power of the sun to power your home, fill out
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The Production of Crystalline Solar Modules

There are 3 types of solar panels available on the market:

monocrystalline solar panels

polycrystalline solar panels

thin film solar panels

Thus, at cell structure level, there are different types of material for manufacturing, such as
mono silicon, polysilicon or amorphous silicon (AnSi). The first 2 kinds of cells have a somewhat
similar manufacturing process. Read below about the steps of producing a crystalline solar
panel.  

Step 1: Sand

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It all starts with the raw material, which in our case is sand. Most solar panels are made of
silicon, which is the main component in natural beach sand.

Silicon is abundantly available, making it the second most available element on Earth.

However, converting sand into high grade silicon comes at a high cost and is an energy intensive
process. High-purity silicon is produced from quartz sand in an arc furnace at very high
temperatures.

Step 2: Ingots
The silicon is collected, usually in the form of solid rocks. Hundreds of these rocks are being
melted together at very high temperatures in order to form ingots in the shape of a cylinder. To
reach the desired shape, a steel, cylindrical furnace is used.  

ingots

In the process of melting, attention is given so that all atoms are perfectly aligned in the desired
structure and orientation. Boron is added to the process, which will give the silicone positive
electrical polarity.

Mono crystalline cells are manufactured from a single crystal of silicon. Mono Silicon has higher
efficiency in converting solar energy into electricity, therefore the price of monocrystalline panels
is higher.

Polysilicone cells are made from melting several silicon crystals together. You can recognise
them by the shattered glass look given by the different silicon crystals. After the ingot has
cooled down, grinding and polishing are being performed, leaving the ingot with flat sides.

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Step 3: Wafers
Wafer

Wafers represent the next step in the manufacturing process.

The silicon ingot is sliced into thin disks, also called wafers. A wire saw is used for precision
cutting. The thinness of the wafer is similar to that of a piece of paper.

Because pure silicon is shiny, it can reflect the sunlight. To reduce the amount of sunlight lost, an
anti-reflective coating is put on the silicon wafer.

Step 4: Solar cells

The following processes will convert a wafer into a solar cell capable of converting solar power
into electricity.

cell

Each of the wafers is being treated and metal conductors are added on each surface. The
conductors give the wafer a grid-like matrix on the surface. This will ensure the conversion of
solar energy into electricity. The coating will facilitate the absorption of sunlight, rather than
reflecting it.

In an oven-like chamber, phosphorous is being diffused in a thin layer over the surface of the
wafers. This will charge the surface with a negative electrical orientation. The combination of
boron and phosphorous will give the positive – negative junction, which is critical for the proper
function of the PV cell.

Step 5: From Solar Cell to Solar Panel

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The solar cells are soldered together, using metal connectors to link the cells. Solar panels are
made of solar cells integrated together in a matrix-like structure.

The current standard offering in the market are:

48 cell panels – suitable for small residential roofs.

60-cell panels – this is the standard size.

72-cell panels -used for large-scale installations.

Panel

The most common sized system in terms of kWh for UK homes is the 4kWh solar system.

After the cells are put together, a thin layer (about 6-7 mm) of glass is added on the front side,
facing the sun. The backsheet is made from highly durable, polymer-based material. This will
prevent water, soil, and other materials from entering the panel from the back. Subsequently, the
junction box is added, in order to enable connections inside the module.

It all comes together once the frame is assembled. The frame will also provide protection
against impact and weather. The use of a frame will also allow the mounting of the panel in a
variety of ways, for example with mounting clamps.

EVA (ethylene vinyl acetate) is the glue that binds everything together. It is very important that
the quality of the encapsulant is high so it doesn’t damage the cells under harsh weather
conditions.

Step 6: Testing the Modules

Once the module is ready, testing is carried out to ensure the cells perform as expected. STC
(Standard Test Conditions) are used as a reference point. The panel is put in a flash tester at the
manufacturing facility. The tester will deliver the equivalent of 1000W/m2 irradiance, 25°C cell
temperature and an air mass of 1.5g. Electrical parameters are written down and you can find
these results on the technical specification sheet of every panel. The ratings will reveal the
power output, efficiency, voltage, current, impact and temperature tolerance.

Apart from STC, every manufacturer uses NOCT (nominal operating cell temperature). The
parameters used are more close to ‘real life’ scenario:  open-circuit module operation

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temperature at 800W/m2 irradiance, 20°C ambient temperature, 1m/s wind speed. Again, the
ratings of NOCT can be found on the technical specification sheet.

Cleaning and inspection are the final steps of the production before the module is ready to be
shipped to homes or businesses.

Research and development in the solar energy industry is aiming at reducing the cost of solar
panels and increasing efficiency. The solar panel manufacturing industry is becoming more
competitive and is forecasted to become more popular than conventional sources of energy,
such as fossil fuels.

If you’re interested in joining thousands of UK homeowners who have already switched to

renewable energy, GreenMatch can help you take the first step. By getting multiple quotes you
can be assured you’re getting the best deal.

Start getting quotes from trusted solar panel installers today, by filling out our 1-minute contact
form! You’ll be offered up to 3 free quotes that you’re able to compare and choose from to find
the best deal. This service is completely free and non-binding!

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