What Is the Manufacturing Process of Solar Panels?

As the world accelerates toward clean energy, solar panels are at the heart of the revolution. But how are these powerful sheets of silicon and glass actually made? Let’s take a closer look at the journey from raw materials to a fully functional solar panel.

Step 1: Silicon Ingot and Wafer Production

The process begins with high-purity silicon, extracted from sand and melted into cylindrical ingots. These ingots are sliced into thin wafers, just a few hundred microns thick. These wafers will eventually become the core of each solar cell.

Step 2: Solar Cell Manufacturing

Each wafer undergoes a series of chemical treatments and is layered with phosphorus and boron to create a positive and negative layer — forming a photovoltaic (PV) cell. An anti-reflective coating is also added to enhance light absorption.

Step 3: Cell Interconnection

Dozens of solar cells are soldered together using metal ribbons to form a panel — this is called the stringing process. These cell strings are then arranged into a matrix.

Step 4: Lamination and Encapsulation

The entire cell matrix is laid between a front sheet of tempered glass and a back sheet of protective material, with EVA (ethylene vinyl acetate) layers in between. This “sandwich” is then heated and laminated to seal the components and protect them from moisture and damage.

Step 5: Framing and Junction Box Installation

A sturdy aluminum frame is added for structural integrity and for mounting purposes. A junction box is attached to the back to allow electrical connection.

Step 6: Testing and Quality Control

Each panel undergoes strict electrical performance testing (IV curve), electroluminescence (EL) inspection, and insulation resistance tests to ensure safety, durability, and efficiency.

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