How to Make a Custom Solar Panel?

A solar panel is a device that converts solar radiation into electrical energy through the photoelectric effect by absorbing sunlight.

 
Then, how to make a custom solar panel?
Following are the several steps about how to make a solar panel.



1. Solar cell testing & cutting.
Solar cells are checked and inspected to ensure no damaged or cracked cells. Then using laser cutting machine to cut the solar cells into small pieces in uniform size, depending on the wattage of a custom solar panel.

2. Solar cell soldering
Using the solar cell stringer machine, solder the ribbons to the front and back surfaces of individual solar cells, and then solder the front side ribbons of a first solar cell to the back side ribbons of the neighboring solar cell to form solar cell strings wired in series. 

3. Laminated laying
After the solar cells are soldered and connected in series and passed the inspection, the solar cell strings, glass, EVA, and back sheets are laid according to a certain level, ready for lamination. When laying, ensure the relative position of the solar cell string and glass and other materials, adjust the distance between the solar cells, and lay the foundation for lamination. (Laying level: from bottom to top: glass, EVA, solar cells, EVA, backsheet).

4. Lamination
The encapsulation of the solar cells through lamination is a crucial step in the production of solar panel. Put the prepared 5-layer solar panels into the laminator, pump out the air in the solar panels by vacuuming, then heat to 135°C for 20 -25 minutes to melt the EVA, to bond the solar cells, glass and backsheet together; finally cool down to take out the solar panels.

5. Trimming
During lamination, after EVA melts, it extends and solidifies to form burrs due to pressure, so it should be cut off after lamination.

6. Frame
Install aluminum frame for glass laminated solar panel to increase the strength of the module, further seal the solar panel and prolong the service life of the solar cell.

7. Welding junction box
Weld a junction box at the lead on the back of the solar panel to facilitate the connection between the solar panel and other devices.

8. Solar panel test
The purpose of the test is to calibrate the output power of the solar panel and test its output characteristics.

9. Cleaning & Packing
Clean the solar panel to remove any dust, foreign particles or extra sealant, then pack them into bags or carton boxes or pallets to ensure safety transportation.
 
WSL Solar has been a quality and professional manufacturer of custom solar panels, solar mini panels, IoT solar panels and solar solution provider in China since 2006.
https://www.wsl-solar.com

Source of origin: https://www.wsl-solar.com/Product_News/2023/0713/how-to-Make-a-Custom-Solar-Panel.html
 

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