A photovoltaic panel is the end result of solar panel fabrication, and the process is designed to convert sunlight into power. Solar cells are created using a variety of materials, including copper, silver, silicon, EVA, glass, aluminium, and ethylene vinyl acetate (EVA). Once the cells are assembled into panels, they are coated with a protective layer, and the panels are tested before distribution and installation.
By understanding the materials involved and the process fabricators take, you can stay better informed about the quality of the solar panels you’re considering when comparing supplier and installation quotes.
Table of contents
The Basics: Solar Panel Fabrication
- A variety of materials are involved in the solar panel fabrication process, from the silicon semiconductor and silver acting as a conductor to the copper wiring and aluminium frame. Each material has a key role to play in the solar panel’s operation.
- There are five key steps: Silicon purification, wafer creation, cell fabrication, panel assembly, and testing.
- It’s important to use quality materials because they can affect the efficiency, performance, durability, and cost of the panels.
How Solar Panels Are Fabricated
Let’s take a closer look at the five key steps in the solar panel fabrication process.
Silicon Purification
Silicon is extracted from quartz sand by melting it down into ingots. Once the silicon is melted down, impurities are removed to ensure purification.
Wafer Creation
The purified silicon is melted to form cylindrical ingots, which are sliced into wafers up to 200 micrometres thick.
Cell Fabrication
Cell fabrication requires wafer doping, which is the introduction of phosphorus and boron to create a p-n junction where the electrons flow when light reaches the cell. Then, aluminium fabricators apply anti-reflective coating to the wafers, which minimises reflection to ensure the cell can absorb all the light.
Panel Assembly
Once the wafers are treated and metal contacts are created, the individual solar cells are interconnected to create a string of cells. Once the cells are strung, they are encapsulated on a back-sheet within layers of EVA and framed in aluminium to ensure the panel is durable.
Testing
Finally, the completed solar panels are rigorously tested to ensure they meet high performance standards, and once they are certified, they can be packaged and shipped.
Solar Panel Fabrication Materials
- Silicon is the core material utilised to convert energyÂ
- EVA is used as an encapsulant to protect the cells against moisture
- Backsheet provides protection and insulation
- Glass is used as the protective top layer
- Aluminium is used as a lightweight, durable frame
Why Does Aluminium Play A Role In Solar Panel Fabrication?
Due to its durability, aluminium is the ideal choice for framing solar panels. It’s resistant to corrosion, lightweight, and strong enough for rooftop installation. Additionally, the existence of recycled aluminium allows for a sustainable step in the fabrication process.
How Fabrication Influences Cost And Performance
As with any fabrication project, the quality of materials matters greatly. Using high-quality materials will ensure the panel is an appropriate weight for rooftop installation, but the materials also play a role in efficiency, lifespan, and warranty.Â
For example, using anodised aluminium creates more durable framing and a high-grade silicon improves performance, which is ideal for the harsh conditions across Australia.Â
While it may lead to higher prices, opting for a more durable, high-performing solar panel system will last longer and deliver greater results. Low-quality materials increase the risk of manufacturing defects, which can lead to microcracks that are detrimental to performance.
The Key Differences: Monocrystalline Vs Polycrystalline Vs Thin Film
| Type of Panel | Fabrication Process | Efficiency | Lifespan | Cost |
| Monocrystalline | Fabricated utilising a single-crystal silicon. | High | Up to 40 years | Monocrystalline panels are on the higher end of the price spectrum. |
| Polycrystalline | Fabricated by melting down fragments. | Moderate | Up to 30 years | Polycrystalline panels are the mid-range option on the price spectrum. |
| Thin Film | Fabricated by layering materials. | Low to moderate | 10 to 20 years | Thin film panels are on the cheaper end of the price spectrum. |
Which Fabrication Method Is The Most Sustainable?
From a fabrication point of view, thin film panels are generally considered the most sustainable option because they consume fewer resources during fabrication. However, when the fabrication process is balanced with efficiency, quality, and lifespan, monocrystalline panels pull ahead. For the length of time they produce clean energy efficiently, investing in a monocrystalline panel gives you more bang for your buck, delivering efficiency rates of up to 15–20%.Â
Solar Panel Fabrication: The Environmental Considerations
Whatever type of panel you prefer, you can look for companies that take the environment into consideration throughout the process. For example, many companies will utilise recycled glass and aluminium. Ultimately, the silicon purification process is energy-intensive, and there are high levels of water and chemicals used throughout.Â
However, some companies embrace green production processes to reduce the impact. So, look out for manufacturers who talk about taking part in panel recycling programs or use recycled glass and aluminium.Â
Why Understanding The Fabrication Process Helps You Choose Solar Panels Wisely
Go Solar Quotes can help you compare quotes and choose a system and installer. Understanding the fabrication process can go a long way to helping you choose wisely.Â
The fabrication process is time-consuming and complex, but you must understand how big a role the process plays in producing high-quality, efficient, durable, sustainable solar panels you can rely on for decades to come.Â
By understanding the process, you can easily compare solar panel quality and make a wise investment when selecting your solar panel system.
