What is Solar Panel Manufacturing?
Solar panel manufacturing is a complex technological process that converts solar energy into usable electricity.
This transformation occurs through the photovoltaic effect, discovered in 1839 by Alexandre Edmond Becquerel, which
enables solar cells to generate electrical current when exposed to light.
The solar panel manufacturing process involves several crucial stages, from raw silicon
extraction to the final installation of photovoltaic modules on rooftops or in solar power plants.
The 7 Fundamental Steps of Solar Production
1. Silicon Extraction and Purification
The first step in solar production begins with extracting silicon from quartz sand (SiO₂).
Silicon accounts for approximately 90% of current photovoltaic cells.
Purification process:
- Reduction of quartz in electric arc furnaces at 3,632°F (2,000°C)
- Production of metallurgical silicon (98% purity)
- Chemical purification via the Siemens process to achieve 99.9999% purity
- Production of solar-grade silicon
This stage consumes enormous amounts of energy, representing about 45% of a solar panel's total carbon footprint.
2. Creating Crystalline Silicon Ingots
Once purified, silicon is melted and crystallized to form cylindrical ingots (monocrystalline) or square blocks
(polycrystalline).
Two main methods:
- Czochralski method: produces monocrystalline silicon with superior efficiency (20-22%)
- Casting method: manufactures polycrystalline silicon, less expensive but with lower efficiency
(15-17%)
3. Wafer Slicing
The ingots are then sliced into thin discs called wafers using diamond wire saws. This
critical manufacturing step determines the final thickness of photovoltaic cells.
Wafer characteristics:
- Thickness: 180 to 200 micrometers
- Material loss: approximately 50% during cutting
- Polished and textured surface to optimize light absorption
4. Solar Cell Formation
This stage transforms wafers into functional cells capable of producing electricity.
Doping process:
- P-type doping: adding boron to create positive charges
- N-type doping: incorporating phosphorus for negative charges
- Formation of the P-N junction, the heart of the photovoltaic effect
Adding electrical contacts:
- Screen printing of conductive pastes (silver, aluminum)
- High-temperature firing to fuse contacts
- Electrical testing of each cell
5. Solar Module Assembly
Individual cells are assembled to form complete solar panels.
Module structure:
- Tempered anti-reflective glass (front face)
- EVA (Ethylene Vinyl Acetate) encapsulant
- Interconnected photovoltaic cells
- Protective backsheet (rear face)
- Aluminum frame for rigidity
Recent innovations in panel
manufacturing include TOPCon and heterojunction technologies, enabling efficiencies exceeding 23%.
6. Quality Testing and Certification
Each solar panel undergoes rigorous testing to guarantee performance and durability:
- Power testing under standard test conditions (STC)
- Electrical insulation testing
- Weather resistance testing
- International certification (IEC 61215, IEC 61730)
7. Installation and Commissioning
The final step involves installing panels at their destination site:
Residential installation:
- Feasibility study using tools likePVGIS24
- Roof or ground mounting
- Electrical connection and commissioning
Commercial installation:
- Large-scale solar power plants
- Grid integration
- Advanced monitoring systems
Emerging Technologies in Solar Production
Perovskite Cells
Perovskite cells represent the future of photovoltaic production with theoretical
efficiencies exceeding 40% in tandem configurations.
Bifacial Cells
These cells capture light on both sides, increasing energy production by 10 to 30% depending on the environment.
Thin-Film Production
An alternative to crystalline silicon, this technology uses less semiconductor material while maintaining good
efficiency.
Environmental Impact and Sustainability
Modern solar production incorporates growing environmental concerns. The environmental impact of solar
energy continues to decrease thanks to technological improvements.
Energy payback time: A solar panel repays the energy used in its manufacture within 1 to 4
years, for a lifespan of 25 to 30 years.
Solar panel recycling
solutions are also becoming crucial, with recycling programs enabling recovery of 95% of materials.
Optimizing Your Solar Project
To properly size your installation, use the PVGIS solar calculator which takes into account:
- Solar irradiation in your region
- Optimal orientation and tilt
- Potential shading and obstacles
- Projected energy production
The PVGIS financial simulator also helps you
evaluate the profitability of your photovoltaic investment.
Future of Solar Production
Photovoltaic manufacturing steps continue to evolve with:
- Increasing automation of production lines
- Reducing manufacturing costs
- Improving energy yields
- Integrating artificial intelligence for optimization
Comparing different production
methods shows that crystalline silicon remains dominant, but alternative technologies are gaining
ground.
FAQ - Frequently Asked Questions About Solar Production
How long does it take to manufacture a solar panel?
Complete solar panel manufacturing, from silicon extraction to finished product, takes approximately 2 to 4 weeks.
However, if silicon purification is included, the process can extend over several months.
What's the difference between monocrystalline and polycrystalline cells?
Monocrystalline cells offer superior efficiency (20-22%) and better low-light performance but are more expensive.
Polycrystalline cells are less costly with 15-17% efficiency but require more space for the same production.
How much energy is needed to produce a solar panel?
Manufacturing a 300W solar panel requires approximately 200-400 kWh of energy, mainly for silicon purification.
This energy is offset within 1-4 years of use depending on the installation region.
Are solar panels recyclable?
Yes, solar panels are 95% recyclable. Glass, aluminum, and silicon can be recovered and reused. Recycling
facilities are developing worldwide to process the first generation of panels reaching end-of-life.
What is the lifespan of a solar panel?
A solar panel has a lifespan of 25 to 30 years with performance warranties typically guaranteeing 80% of initial
power after 25 years. Some panels can continue operating beyond 30 years with gradual degradation.
How is quality controlled during production?
Each production stage includes quality controls: electrical testing of cells, visual inspection, mechanical
resistance tests, independent laboratory certification, and performance testing under standard conditions.
Which countries dominate global solar production?
China represents approximately 70% of global solar panel production, followed by Malaysia, Vietnam, and Germany.
Europe and the United States are also developing their production capacity to reduce dependence.
Can the efficiency of existing panels be improved?
Once manufactured, a panel's efficiency cannot be improved. However, installation optimization (orientation, tilt,
cooling systems) can maximize production. New generations now achieve over 23% efficiency.
To deepen your photovoltaic knowledge and optimize your solar project, consult our complete PVGIS guide and discover our detailed
documentation reserved for premium subscribers.
