RETC PV Module Index Report 2024
RETC PV Module Index Report 2024
PV Module
Index Report
[Link]
A LETTER FROM OUR CEO
A
s RETC publishes its sixth annual PV Module Index Report, our organization
has never been better positioned to support the global energy transition.
As a member of the VDE Group, RETC provides customers worldwide
with a one-stop shop for solar and energy storage product testing, inspection,
and certification. Moreover, RETC is uniquely positioned to support the nascent US
clean energy manufacturing renaissance.
Since the passage of the Inflation Reduction Act in 2022, companies have announced
nearly $17 billion worth of investments in new and expanded solar manufacturing
capacity additions in the United States. Given the unprecedented market expansion
in the world’s second-largest solar market, industry stakeholders must remain
vigilant regarding technical risks inherent to supply chain diversification and the
accelerated time frames between innovation and mass production.
As a highly accredited independent testing laboratory, RETC is privileged to receive a sneak preview of coming solar
technologies and trends. Based on this perspective, we can confidently say that the future is largely a sunny and innovative
place populated with new and exciting technologies. However, it is not a place without risk or cloudy weather. For example,
RETC has long warned industry stakeholders about potential field durability risks intrinsic to ultra-large-format PV modules.
In our laboratory testing, RETC has consistently observed that heat-strengthened solar glass is more prone to breakage than
fully tempered solar glass. Unfortunately, we now suspect this vulnerability may also apply to field deployments. We have
therefore dedicated the entirety of the “Industry Trends” section (pp. 5–15) to subject matter expert interviews exploring reports
of spontaneous glass breakage and catastrophic hail losses in fielded solar assets. Our hope is that this candid discussion will
inspire a collective response that ultimately eradicates the problem.
RETC is united with its customers in the belief that our collective work enables a safer and more sustainable future. Thank you
for being our partners and collaborators in this endeavor.
—Cherif Kedir, CEO, RETC
Industry Trends 5
Module Reliability 18
Reliability Indicators and Results 18
Backsheet Ultraviolet Durability Test (BUDT) 19
Damp Heat (DH) 19
Hail Durability Test (HDT) 20
Potential-Induced Degradation (PID) 21
Static and Dynamic Mechanical Load (DML) 22
Thermal Cycling (TC) 23
Ultraviolet-Induced Degradation (UVID) 24
Module Performance 25
Performance Indicators and Results 25
Module Efficiency 26
Incidence Angle Modifier (IAM) 27
Light- and Elevated Temperature–Induced Degradation (LETID) 27
Light-Induced Degradation (LID) 28
PAN File Characterization 29
PTC-to-STC Ratio 30
Temperature Coefficient 31
Module Quality 32
Quality Indicators and Results 32
Red Flags 33
Cover Photo: ryanking999 / [Link]
A Year in Review 35
rh2010 / [Link]
2024 Awardees 37
2024 Summary of Results 38
Looking Ahead 39
ABOUT RETC
RETC (Renewable Energy Test Center), a member of the VDE Group,
is a leading provider of engineering services and certification testing
for renewable energy products. Since its founding in 2009, RETC has
partnered with manufacturers, developers, and investors to test a wide
range of products, including solar PV modules, racking, trackers, power
electronics, and battery energy storage systems (BESS). At our accredited
laboratories around the world, we evaluate products using only the latest
testing standards and industry-accepted methods. Headquartered in
Fremont, California, RETC puts customers at the forefront by bringing
value to research and development, bankability assessments, and market
entry. We are united with our customers in the belief that our work enables
a safer and more sustainable world.
I
n the 2021 edition of the PV Module Index Report, RETC for environmental stresses? Were our testing protocols
explored the benefits and trade-offs associated with and sequences inadequate to identify potential new failure
a then-novel trend toward large-format PV module modes and wear-out mechanisms?
designs. On the one hand, we noted that large-area, high-
power modules were helping to accelerate the process Today, our in-house laboratory and field forensic investigations,
of lowering the levelized cost of energy (LCOE) of solar, not to mention insightful due diligence from esteemed
effectively making flat-plate PV technologies more cost- colleagues worldwide, better inform us. With the benefit of
effective compared to other sources of power generation this experience and hindsight, we find ourselves asking: Is
capacity. On the other, we noted that the up-front cost a decline in the compressive strength of solar module glass
savings associated with these value engineering efforts partly to blame for some of the unique field failure modes
could come at the cost of reduced resilience to conditions associated with new ultra-large-format module designs?
of use, including exposure to elevated wind and snow loads
or severe hail impacts. This is an elephant-sized question that we, like the blind
persons in the parable, cannot describe fully by touching
Some three years later, the early warning efforts documented only one part of the beast. With that in mind, we interviewed
in our article, “Evaluating Large-Format PV Modules,” are a handful of industry subject matter experts, each of whom
simultaneously prescient and naive. While we had clearly brings a unique perspective and area of expertise to the
identified a signal in our laboratory testing and field table. By questioning these many authorities—on glass
forensics—namely, structural vulnerabilities associated with manufacturing, module durability, field forensics, tracker
newer module designs—we did not necessarily understand structures, and hail-impact characterization—and sharing
the root cause of the issue. Was the physical size of these those conversations here, we hope to empower industry
new modules a problem? Was solar market proliferation to stakeholders to eliminate a potential technical barrier to
blame for subjecting modules to previously unaccounted- solar market advancement.
DR. JAMES WEBB is a senior RETC: How does heat-strengthened glass differ from
research manager for reliability tempered glass?
sciences at Corning, a pioneering
glass manufacturer founded in 1851. JW: The best way to understand these differences is to refer to
Today, Corning provides state- ASTM C1048 Standard Specification for Heat-Strengthened
of-the-art products for a variety and Fully Tempered Glass. This standard differentiates
of industrial applications, such as between fully tempered and heat strengthened based on
optical communications, mobile consumer electronics, surface stress levels and breakage patterns. For example,
displays, automotive supplies, and life sciences. Dr. the standard defines tempered glass as having a minimum
Webb’s research, development, and engineering activities surface tension of 69 MPa, whereas heat-strengthened glass
are foundational to the company’s product and process will have a surface compressive strength of 24 to 52 MPa.
innovations for ceramics and specialty glass. In terms of breakage patterns, the stress level in tempered
glass is intended to ensure that for improved safety, the
RETC: What are the challenges associated with using glass glass breaks into small cube-shaped pieces of glass rather
as a structural material? than sharp jagged shards. While fully tempered glass
meets building code requirements for safety glass, heat-
JW: Glass is a unique material that is largely used for two strengthened glass does not. Annealed glass [ordinary float
main properties: chemical stability and visual transparency. glass] has a surface compression of less than 24 MPa and
Certainly, glass is not commonly used as primary beams may fracture as sharp shards, which can pose a risk of injury.
supporting a building, but people do use it, in a sense, to
manage applied loads. What is interesting about glass as a RETC: Is there a relationship between glass thickness and
structural material is that its strength is largely an extrinsic heat strengthening?
property, meaning it is a function of something you do to
the glass that changes its strength. The strength of best- JW: When a piece of glass is tempered, its temperature is
in-class commercially available glass optical fiber is on the raised to between the annealing and softening temperatures,
order of 10 to 14 gigapascals, which approaches theoretical where the glass can adjust its own stress quickly. Then it
limits. By comparison, the practical strength of plate glass is quickly cooled. During cooling, the glass surface shrinks
is multiple orders of magnitude lower, on the order of 70 first, while the interior of the glass still has the ability to
to 100 megapascals (MPa). What dictates glass strength is flow. Surface compression then develops as the interior
largely what manufacturers do to the surface. For example, completes its process of cooling, shrinking, and solidifying.
heat tempering adds compressive strength to the surface This results in tensile stress in the center of the glass and
of the glass. This compressive strength provides protection compressive stress on the exterior surface. What drives the
against surface flaws that would otherwise change the tempering process is the manufacturer’s ability to develop
glass’s inherent strength. Flaws resulting from manufacturing a temperature differential through the thickness of the glass.
processes, handling processes, or environmental exposure
will reduce structural strength in glass. RETC: Is it possible to fully temper thinner sheets of glass?
TEMPERED GLASS
Teresa Barnes, Ph.D., manages the RETC: Do you and your colleagues have any theories about
Photovoltaic Reliability and System why this is happening?
Performance Group at NREL.
She is an expert in accelerated TB: We have started to hypothesize internally about potential
test development, outdoor field root causes. At DuraMAT, for example, we funded a bunch of
testing, energy yield assessment, projects on cell cracks with the idea that researchers would
degradation rate analysis, and take PV modules, pre-crack the cells, and then do some sort
materials science. In addition to working with stakeholders of stress test to identify the impact of the latent defect. After
throughout the PV value chain to develop industry standards funding this research, I started receiving phone calls and
for reliability testing and energy yield, Dr. Barnes is also emails saying: “Hey, I can’t break the cells without breaking
the principal investigator and director of the DuraMAT the glass. It seems like cell cracking is not our problem right
Consortium for module materials research. now. Can I look at glass breakage or something else instead?”
What we believe is happening is similar to how your car
RETC: Has NREL noted any changes in glass breakage windshield breaks, where a small surface defect propagates
patterns over time? when exposed to an extreme environmental stress. Think
about when you are driving down the road and something
TB: Spontaneous glass breakage is an example of a failure hits your windshield. The windshield probably does not
mode that we didn’t used to see. When I first started shatter on impact. Instead, you might see a small star-
working on solar module reliability seven or eight years shaped defect on the surface of the glass. Here in Colorado,
ago, we mostly heard about glass breakage when there where I go through more windshields than I ever did on the
were sloppy O&M [operations and maintenance] practices. East Coast, that impact damage might not propagate until
Maybe someone is mowing for vegetation management, there is a dramatic change in the weather. But when I walk
the mower throws a rock, and you get glass breakage. outside on the first really cold day of winter, suddenly all
Occasionally, we would hear about glass breakage in thin- the windshields in my driveway have a big crack all the way
film modules, which use thinner glass that is not tempered; across the glass. We think a similar dynamic could be a root
this is known failure mode, one that we would expect to cause of spontaneous solar glass breakage.
see. Outside of these known issues, we didn’t used to hear
about glass breakage in silicon modules unless there was a RETC: Why do you think this failure mode is increasing now?
catastrophic storm. That is no longer the case. Now we are
regularly hearing about glass breakage in silicon modules. TB: Solar glass is thinner today than it was in the past. Because
While these reports are anecdotal, there is a definite pattern. the glass is thinner, it is not fully tempered. According to
People are seeing glass breakage for no apparent reason, glass experts like Mike Pilliod from Central Tension, who
often before commissioning. These field reports track what spoke at NREL’s 2024 PV Module Reliability Workshop, any
we are hearing from the testing labs. It used to be the case manufacturer can temper glass that is 3 mm [0.12 in.] or thicker
that modules would pass the IEC 61215 static load test with because it is relatively easy to get the thermal differential to
a big safety factor. Today, modules are either barely passing build the stress profile you need. However, it is more difficult
the base static load test or they are not passing with higher to fully temper glass below a thickness of 3 mm. If you do not
safety factors. Some new module designs are simply not have a good temper on the glass, it is relatively easier for the
passing the minimum static load test. glass to break. In other words, as solar glass gets thinner, it
takes fewer defects to cause a strength-limiting flaw in the
glass. Moreover, the way we specify glass in the solar industry
“As solar glass gets thinner, it takes right now does not account for strength-limiting flaws in glass
that is not fully tempered. There might be a ball-drop test on
fewer defects to cause a strength-
a piece of glass, but people are not necessarily looking at the
limiting flaw in the glass.” impacts of defects around the edges of the glass. Also, the
—Teresa Barnes, Ph.D., NREL way people are cleaning or grinding around the edges of the
glass may be causing more defects rather than fewer defects, about frames getting a bit more substantial and mounting
perhaps making this thinner glass even more sensitive to rails getting a bit wider. As people better understand how
breakage. These are the types of things that we are starting the module system interacts, they can work to optimize
to investigate and trying to better understand. how loads are balanced out. The pendulum in that balancing
act may already be swinging back toward the integrity of
RETC: How does glass breakage relate to module frame the frame and the mounting rail.
and rail designs?
RETC: Given the catastrophic scale of recent hail loss
TB: There is undoubtedly an interaction between these events in Texas, do you think the industry needs hail-
different components. A module is really a whole system, hardened module designs?
often consisting of glass, a perimeter frame, and a mounting
rail. When you think about ultra-large modules as a system, TB: Ten years ago, people would run you out of the meeting
the glass may be getting thinner, the frame may be getting on a rail if you mentioned climate-specific module designs.
thinner, and the mounting rails may be getting closer The consensus was that this would simply be too expensive.
together. The interaction between these components is A decade ago, module cost was really the barrier to entry.
where the term “big floppy modules” comes from. While Today, solar is a terawatt-scale industry, and we are deploying
glass has always been an element in the module system, it hundreds of gigawatts of solar capacity annually. Now climate-
may be bearing more of the load now, which may be bad specific modules and climate-specific testing are starting to
because we have made the glass weaker. look viable because we are seeing more of an emphasis on
total system costs. It is entirely possible that we could see
RETC: How has the industry responded to reports of hail-hardened modules, especially in a market like the United
spontaneous glass breakage? States, where it could be worth paying more up front for hail
resilience. At the end of the day, a lot of these design decisions
TB: At this year’s PV Module Reliability Workshop, my will come down to the business model. People flipping and
colleagues and I started to hear about frames getting selling projects will always have different priorities than those
thicker again. This was somewhat surprising, given the rapid who own and operate projects for the long term. If you are the
innovation in recent years focused on making modules person who will be caught holding the bag when a hailstorm
cheaper and lighter. The problems we are seeing in the US comes, maybe you are willing to pay a little more for hail-
market may be causing manufacturers to rethink product hardened solar modules—because that decision helps make
design strategies. We are starting to hear some chatter the system pencil over a long lifetime.
Ralf Schulze manages field environmental stress factors have always been there, they
forensics services for RETC. A 15- were not the leading cause of glass breakage. Today, we are
year veteran in the renewable sometimes being called to investigate glass breakage at sites
energy sector, he has worked as a where modules seem to be failing under normal conditions
managing engineer at Kaco new of use. While I have not seen that many impacted sites, a lot
energy and Yingli Green Energy of people within the broader community are seeing similar
Americas and as a quality manager problems. We know this because NREL and DuraMAT share
for Sunrun. A renowned source for end-to-end renewables information regarding field failures relatively quickly. For the
technology problem-solving and specialized services, few sites I have investigated—which are large utility projects
Schulze is an expert in quality assurance, failure mode and on the order of 100 MW–300 MW in capacity—we are seeing
effects analysis, system diagnostics, and corrective and spontaneous glass breakage rates of 2%–5%.
preventative maintenance.
RETC: Is there a typical field forensics process for
RETC: What is your experience with glass breakage in investigating glass breakage?
fielded PV systems?
RS: When we want to pinpoint a root cause, the first step is
RS: Glass breakage in the field is not necessarily a new to isolate each individual problem, starting with the terrain,
phenomenon. Over the years, we have documented glass tracker, installation process, mounting hardware, torque
breakage in utility solar due to terrain issues, sinking piles, settings, and so forth. Then we start to look for patterns.
construction errors, installers using impact tools, and Is the glass breaking at the mounting rail locations? Is the
incorrect torque settings—the list goes on and on. Having glass breaking during the installation process or after the
said that, my personal experience suggests that the leading commercial operations date? Has the site experienced
causes of glass breakage may be changing over time as PV a severe weather event and been subjected to pressure
modules become larger, using thinner glass and reduced ratings beyond the allowable design loads? When there is
frame profiles. In more recent glass breakage investigations, a pattern that repeats itself—either across a site or based
we are seeing signs pointing to the glass itself, which is not on experience—we can identify a particular issue as the
fully tempered anymore. likely root cause. When breakage patterns are random, that
could suggest the glass itself is not suitable for the specific
RETC: How does module glass specification impact project installation environment. In other words, if we see breakage
durability? inconsistent with anything we have seen in the past, it could
be because the glass is not fully tempered.
RS: Laboratory testing clearly indicates that thin, heat-
strengthened glass has higher breakage and failure rates as RETC: Who is most impacted by spontaneous glass breakage?
compared to fully tempered glass. While thinner glass may
be an ideal way to keep module costs and weight down, RS: The parties feeling the pain tend to be the EPC, project
there may be other considerations to balance, especially owner, or whoever builds the project and then wants to
with large-scale modules. Stress on module glass in the field transfer it to a final owner. If glass breakage is documented
is substantial, especially in the east and west corners of the during the commissioning and handover process, it leads
array under certain wind or weather conditions. While these to bigger questions. People will ask, “If spontaneous glass
breakage is happening to some modules now, won’t it
“When breakage patterns are happen to the other modules, too?” This type of scrutiny
random, that could suggest the glass is uncomfortable for the module manufacturer, who will
generally try to help mitigate the problem. From professional
itself is not suitable for the specific
experience, I believe PV module manufacturers are aware of
installation environment.” these issues, and I suspect some manufacturers are starting
—Ralf Schulze, RETC to rethink module construction practices.
RS: There are many aspects to this type of technical due RS: Ideally, laboratory testing is done as part of a systematic
diligence. First, you need to investigate and fully test vendor qualification program that starts with long-term
the resiliency of the glass, especially with ultra-large- durability testing—such as RETC’s Thresher Test—followed
scale module designs. Hail durability testing is the most by 12 to 18 months of in-field monitoring. Once you have
likely to identify vulnerabilities associated with the glass qualified vendors and identified resilient BOMs [bills of
itself. Importantly, this testing must exceed the minimum materials], you need to verify that the product leaving the
standards for product certification. Second, you need factory matches the BOM you have locked down. So if you
to understand how module frame and tracker mounting are building a 1 GW project over a period of years, you need
rail details impact module resilience to glass breakage. to require monthly BOM verification inspections and ongoing
Static and dynamic mechanical load sequences are random sample testing to ensure the product you approved
useful for investigating module glass vulnerabilities is being delivered to the field. Once the product reaches
related to the frame and rails. This type of testing has the project site, look for smart ways to improve installation
consistently shown a tremendous decay in load-bearing practices as modules increase in area. For example, you
capacity whenever module frame profiles drop below 35 may be able to optimize installation quality using robotic
millimeters [1.38 in.]. suction-cup machines for module handling.
Scott Van Pelt is the chief RETC: What is the goal of mechanical load testing to
engineer for GameChange Solar, failure?
a manufacturer of fixed-tilt and
single-axis tracker solar mounting SVP: We are testing to identify the lightest rail required to
systems. Licensed as a professional meet the desired mechanical capacity. To better align with
engineer in 20 states, he functions wind tunnel test results conducted by our wind engineering
as the structural engineer of record consultant, CPP Wind, we conduct unbalanced load testing,
for many of the company’s projects and is responsible for which subdivides the module into four different segments.
the execution, accuracy, and timeliness of its technical Rather than applying a uniform pressure across the entire
deliverables. Van Pelt is an expert in structural engineering surface of the module, which is an under-conservative design
who has served as a member of several national and assumption, we apply unbalanced loads that reflect how
international standards committees. the wind actually loads tracker-mounted modules during
operation. If the site and technology details are known, we
RETC: How does tracker specification impact PV module can conduct this testing using pressures informed by site-
resilience? specific parameters, such as design windspeed and ground
cover ratio. Alternatively, we can calculate pressures for a
SVP: When we examine a solar module’s load-bearing generic project, based on slightly conservative assumptions
capacity under mechanical testing in the laboratory, we informed by building codes and industry practices. RETC will
see that this property is not inherent to the module itself then perform the specified unbalanced load testing, which
but rather a function of the solar module and the mounting is highly indicative of module loading during operation.
rail acting as an assembly. In other words, the strength of a
tracker-mounted solar module is derived in part from the RETC: How does unbalanced load testing impact single-
mounting rail. Specifically, the stiffer the rail and the longer axis tracker design?
the rail—the further the rail extends out from the center of the
module—the higher the mechanical support capacity for the SVP: There is no meaningful difference from the torque tube
assembly. In this context, I am using the term “rail” somewhat down. However, this testing could cause us to use heavier
ubiquitously. GameChange offers different module mounting components for the torque tube and rails. All single-axis
rail options, including a bolt-and-nut bottom-mount system trackers have a torque tube that rotates the modules, which are
and a friction-fit clamping system called SpeedClamp that attached to the tube using some type of mounting rail system.
offers installation speed advantages. Other vendors offer When we analyze this mounting rail structure, we idealize it as
similar products. Regardless of what rail you are using, you two cantilevers extending out to the east and west sides of the
typically need to increase length or thickness—or both rail torque tube. Based on our wind tunnel test results, we know
length and thickness—to reach higher mechanical ratings. that the wind pressures on these cantilevers are not uniform.
Interestingly, the module itself is generally the weakest link The wind pressures are greatest on the cantilever supporting
in this system. We conduct mechanical testing at RETC, the leading edge of the modules and lower on the cantilever
and the vast majority of the time, the module is the first on the leeward side. Unbalanced load testing ensures that our
component to fail. tracker component designs can support the applied pressure
on the more heavily loaded side of this cantilever. While
unbalanced load testing could possibly cause us to use more
“If you put on your forensic engineer’s heavy mounting rails, the additional cost for these heavier
hat, this module breakage pattern is components is minuscule compared to the remediation costs
indicative of a failure to account for in the event of a field failure.
RETC: Is spontaneous glass breakage something the JP: We are seeing more glass breakage due to hail because
engineering community is tracking? of the expansion of projects into hail-prone regions like
Texas and the Midwest. The risk is exacerbated by larger,
JP: We have heard reports of a couple of incidents of bifacial modules that use 2.0-mm [0.08-in.] glass for both
spontaneous glass breakage from credible sources. While front and back sides. The benefit of 2.0-mm double-glass
it’s unclear why it’s happening, we have some theories. One bifacial modules is that they are not subject to the Section
possibility is that the length of the rails that connect the tracker 201 tariff, and their larger format provides economies of
torque tubes to the modules is too short to provide enough scale cost reductions. The downside is that 2.0-mm glass
support for the design wind load, which allows the modules to is too thin to be fully tempered in most mass-production
bend in the wind and causes the glass to crack. Another theory glass manufacturing lines. Because 2.0-mm glass is heat
is that glass is breaking due to manufacturing defects, which strengthened or semi-tempered only, it’s softer and more
could be inclusions, particles of pollutants in the glass, or other vulnerable to hail damage as compared to fully tempered
manufacturing process problems. Glass breakage could also glass, which is what we have with 3.2-mm [0.13-in.] front
be a construction issue, such as module clamps being torqued glass products. Unfortunately, modules of all kinds are
down with too much force during installation. being deployed in hail-prone regions without sufficient hail
monitoring and stow protocols in place.
RETC: How can project stakeholders prevent spontaneous
glass breakage? RETC: Is it possible to prevent catastrophic losses due to hail?
JP: To address this risk, you can ask the engineer of record JP: Buying modules manufactured with fully tempered front
and independent engineer to check the length of the glass will increase first costs but decrease financial exposure
rails. We often see letters from PV module manufacturers due to hail risk over the investment hold period. Module glass
confirming that rails are long enough, but without providing that is 3.2 mm or thicker is fully tempered and roughly twice
any supporting calculations. Since this issue isn’t covered as resilient to hail impacts as thinner heat-strengthened
under the PV module warranty, it’s important to get an glass. We are aware of manufacturers evaluating different
hail-hardened module design approaches, such as using
thicker 4.0-mm [0.16-in.] front glass or using much thinner
“We are seeing more glass breakage chemically treated front glass layers, like Gorilla Glass. While
due to hail because of the expansion using hail-hardened modules is the best solution to the
problem, all is not lost if you cannot. You can significantly
of projects into hail-prone regions like
reduce the risk of hail damage by using trackers that can put
Texas and the Midwest.” the modules into a steep stow position prior to a hailstorm.
—Jon Previtali, VDE Americas For material hail risk mitigation, we are talking about
O
ur sixth annual PV Module Index Report compiles
Quality
Indicators
the results of beyond-certification bankability
tests conducted at our highly accredited
independent testing laboratories over 12 months, spanning
Q2 2023 through Q1 2024. As with previous editions of the
report, we catalog testing sequences and data according to
three interrelated and equally influential disciplines: module
reliability, performance, and quality.
Introduced at the 2011 PV Module Quality Assurance Forum,
The bankability tests underlying this report are foundational the Thresher Test is the solar industry’s first-ever commercial
to a science- and engineering-based approach to technical reliability and durability analysis standard for PV modules.
risk mitigation. Industry stakeholders can use these The program takes its name from a type of farm equipment
comparative test results to identify product or project used to separate high-quality seed and grain from low-
designs best suited to a specific environment, location, or quality straw and chaff. Much as a threshing machine beats
portfolio, as determined by RETC’s Thresher Test results. plants to separate organic materials according to utility and
desirability, the Thresher Test uses highly accelerated stress
sequences to separate high-quality PV module designs from
low-quality ones.
“To separate the
wheat from the chaff, Having served as the development program coordinator,
the Thresher Test RETC was the first testing laboratory in the world to offer
the Thresher Test. In the years since its adoption as the de
development team facto standard for comparative PV module testing, RETC has
expanded standard adapted or added testing sequences to better align outcomes
accelerated testing with the latest field-failure data. By evolving to meet the
needs of a dynamic industry, RETC’s Thresher Test remains
sequences to much longer cycles
the gold standard for identifying product- or technology-
and times.” specific design vulnerabilities, wear-out mechanisms, failure
—Hugh Kuhn, Thresher Test Program Lead modes, and long-term degradation patterns.
PO
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• Meet high achievement requirements in the
PV
RT
HIGHEST ACHIEVER reliability and performance disciplines
• Meet criteria for recognition in the quality
Longtime readers of the PV Module Index Report may discipline
notice a realignment of our testing data reporting and
evaluation criteria in this 2024 edition. Specifically, we have
reengineered our high-achievement categories by adding OD
ULE
INDEX
RE
PO
M
PV
RT
granularity and raising the bar for our most prestigious HIGH ACHIEVEMENT IN
three of the seven test sequences within the
RELIABILITY reliability discipline only*
awards. These structural changes reflect our internal
commitments to continuous improvement, optimization of
stakeholder value, and quality assurance.
INDEX
ULE RE
OD
Starting this year, manufacturers must successfully 2024 • Meet high achiever requirements for at least
PO
M
PV
RT
complete RETC’s rigorous Thresher Test program and excel
HIGH ACHIEVEMENT IN
three of the seven tests sequences within the
PERFORMANCE performance discipline only
across multiple tests within the reliability and performance
disciplines to receive “Overall Highest Achiever” recognition.
Stepping down from our top honor, RETC will recognize
manufacturers that excel across multiple testing sequences ULE
INDEX
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OD
2024 PO
M
RT
• Meet the high achiever requirements for one
in Reliability” or “High Achievement in Performance.” To
TEST CATEGORY or more individual test sequences only
HIGH ACHIEVER
P
roduct certification and qualification are essential design and product procurement. All solar modules and
first steps on the road to reliability. To characterize installation environments are not the same. Success or
long-term in-field reliability, industry stakeholders— failure in the field could come down to this simple question:
including subject matter experts at RETC—have developed What is the right tool for the job? Successful solar project
enhanced testing standards, procedures, and sequences deployment demands differentiated products and design
that go beyond minimum product safety and design approaches. These strategic design adaptations ensure
qualification requirements. These beyond-qualification test that fielded projects can withstand site-specific risks while
protocols put additional stress on modules to identify areas optimizing investor returns.
of weakness and better predict long-term in-field reliability.
RELIABILITY INDICATORS & RESULTS
Informed by the comparative results of highly accelerated For the 2024 edition of the PV Module Index Report, RETC
stress testing, diligent project developers, owners, and identified seven important reliability evaluation categories.
insurers can take science- and engineering-based steps to As summarized in the “Reliability Discipline Criteria” table,
mitigate severe weather risks and prevent catastrophic loss each category correlates with a specific extended testing
events. Laboratory testing data clearly show that some PV sequence. The source data in this discipline derive from either
modules are more resilient to severe hail impacts, for example, RETC’s Thresher Test or its Hail Durability Test programs.
whereas other products are more vulnerable. At the same time, Within individual categories, we recognize manufacturers of
products that test well for hail durability may be at an elevated products that exceed carefully calibrated reliability indicator
risk of degradation when installed in a hot, humid location. thresholds as test category high achievers. In the year-in-
review section (p. 35), we further showcase manufacturers
Intelligent solar project development eschews an of products that consistently exceed our high achiever
oversimplified solar-as-a-commodity approach to project requirements in the reliability discipline.
For PV modules with glass-on-backsheet packaging, there Reviewing the aggregated data in this testing sequence,
is a strong correlation between module reliability and RETC notes that newer high-efficiency PV module
backsheet durability. The polymeric backsheet’s role is technologies appear more susceptible to damp heat as
to protect the PV cells and interconnects from moisture compared to more mature aluminum back surface field
intrusion, environmental contamination, corrosion, and (Al‑BSF) PV cell technologies. Moreover, these vulnerabilities
degradation. Ultraviolet (UV) aging is the primary aging seem to be increasing over time. This downward trend
factor for polymeric backsheet materials. In a worst- indicates that module companies must pay better attention
case scenario, UV aging can cause backsheet cracking, to DH test results when qualifying new products for market
compromising module performance and safety. entry. In double-glass module designs, for example, it is a
DH SEQUENCE
BUDT* HIGH ACHIEVERS 40%
Manufacturer (in alphabetical order)
JA Solar 35% 36%
LONGi Solar
SolarSpace 30%
*Applies to glass-on-backsheet models only.
Percentage of Modules
25%
POTENTIAL-INDUCED DEGRADATION
(PID)
RETC’s Thresher Test includes a PID testing sequence to sequence calls for a 192-hour duration of exposure (PID192),
characterize a PV module’s ability to withstand degradation double that required for product certification (PID96).
due to shunting (PID-s) and surface polarization (PID-p). This
sequence places rack-mounted modules in an environmental PID risks vary according to cell technology. Traditional Al-
chamber, which controls temperature and humidity, and BSF technologies are at risk of PID-s. New high-efficiency
exposes them to a voltage bias of several hundred volts with cell technologies (such as p-PERC, n-TOPCon, and n-HJT) are
respect to the mounting structure. The Thresher Test PID vulnerable to both PID-s and PID-p. While some amount of PID
is reversible with UV light exposure, NREL has shown that this
recovery is not field representative. As a result, we expect that
the rear-side post-PID UV light soak step will be removed from
PID SEQUENCE both the IEC 61215 standard and the Thresher Test.
60%
Percentage of Modules
static mechanical loading, dynamic mechanical loading 40%
subjects PV modules to 1,000 cycles of +1,000 pascal (Pa)
and –1,000 Pa loads at a frequency of three to seven cycles
per minute. Subsequently, test samples in an environmental 30%
For test category high achiever recognition in the 2024 PV considered maximum power degradation greater than or
Module Index Report, RETC required that PV module models equal to 5% to be a red-flag result. In this testing category,
withstand SDML exposure with less than 2.5% degradation we note that 68% of samples qualified as high achievers
in maximum power. At the other end of the spectrum, we whereas 7% returned red-flag results.
SDML KEY
TAKEAWAYS
• 68% of models tested met
SDML high achiever criteria.
• 11 different manufacturers
were SDML high achievers.
55%
For test category high achiever recognition in the 2024 PV
50% 52% Module Index Report, RETC has required that PV module
45%
models withstand TC600 exposure with less than 2%
degradation in maximum power. At the other end of the
Percentage of Modules
40%
spectrum, we considered maximum power degradation
35% greater than or equal to 5% a red-flag result. In this test
30% category, we note that 67% of samples qualified as high
achievers whereas 9% returned red-flag results.
25%
20%
15%
15% 15% TC KEY TAKEAWAYS
10%
9% 9% • 67% of models tested met TC high achiever
5%
criteria.
0% 0%
0–1.00 1.01–2.00 2.01–3.00 3.01–4.00 4.01–5.00 ≥5.00
• 9% of models tested returned a TC red-flag
Power Loss (%)
result.
TC SEQUENCE HIGH ACHIEVERS
Aptos Solar, Astronergy, ES Foundry, Gstar, JA Solar, LONGi Solar, • 11 different manufacturers were TC high
Qcells, Runergy, SolarSpace, Trina Solar, and Yingli Solar met our
achievers.
TC test category high achiever criteria.
T
o meet investor expectations, solar project engineers Quality
Indicators
must be able to accurately and confidently model
energy yields for any project location. This is
exceedingly difficult given the rapid rate of technological
innovation and solar market expansion. From a materials during product development. In parallel, our work assures
science or mechanical engineering perspective, PV modules owners, insurers, financiers, and independent engineers
today are substantially different from those the industry that mass-produced PV products will perform as expected
installed just five or ten years ago. Meanwhile, solar has during commercial operations. Our state-of-the-art testing
eclipsed other energy sources to become the leading laboratories use calibrated and certified equipment under
source of new power generation capacity globally. audited and controlled conditions. Performance characteristics
captured under these rigorous testing conditions represent
As solar projects increase in scale, number, and distribution, the true measure of PV module performance.
project stakeholders must remain vigilant regarding
performance risks. How do different technologies perform PERFORMANCE INDICATORS
under low-irradiance conditions or in relation to changing & RESULTS
sun angles? Is a specific bill of materials susceptible to For the 2024 PV Module Index Report, RETC identified
irradiance- or temperature-induced degradation under seven important performance evaluation categories. As
expected conditions of use? Will modules and systems summarized in the “Performance Discipline Criteria” table,
perform as expected under the peak power conditions the categories include specific extended testing sequences
critical to energy yield optimization? Laboratory data allow as well as important figures of merit. The source data in this
for a science- and engineering-based understanding of both discipline derive from either RETC’s Thresher Test or our
short- and long-term PV system performance. California Energy Commission (CEC) testing. Within individual
categories, we recognize manufacturers of products that
As a highly accredited provider of product certification exceed thoughtfully calibrated performance indicator
and bankability testing, RETC plays an essential role in PV thresholds as test category high achievers. In the year-in-
performance characterization and optimization. Our laboratory review section (p. 35), we further showcase manufacturers
and outdoor testing services help manufacturers identify cell- of products that consistently exceed our high achiever
level degradation mechanisms and module-level failure modes requirements in the performance discipline.
10%
MODULE EFFICIENCY
KEY TAKEAWAYS
5% • 56% of models tested met efficiency high
4% 4% 4% achiever criteria.
IAM is an important part of a module’s PAN file, a performance 88% at a 70° angle of incidence (AOI) as test category high
characterization software file that informs energy production achievers. This level of performance is indicative of a low-loss
and financial performance models. Specifically, IAM accounts optical design under typical conditions of use. We have not
for how much light transmits through the surface of the applied red-flag criteria in this category. In this testing category,
module glass and encapsulants and reaches the PV cell when we note that 27% of samples qualified as high achievers.
the solar angle of incidence is not normal to the plane of the
array. IAM measurements are essential for understanding LIGHT- & ELEVATED TEMPERATURE–
module performance at different times and seasons, INDUCED DEGRADATION (LETID)
especially early or late in the day or in wintertime when the RETC’s Thresher Test program requires a LETID testing
sun is more frequently closer to the horizon. It is also relevant sequence to investigate a product’s susceptibility to light-
for understanding geographical affects, such as module and elevated temperature–induced degradation. This
performance at latitudes farther from the equator. sequence includes three 162-hour rounds of 75°C (167°F)
temperature exposure in an environmental chamber while
In the 2024 PV Module Index Report, RETC has recognized connected to a power supply simulating maximum power
manufacturers of PV module models with an IAM greater than operation under full sun conditions. The sequence also
incorporates a boron-oxygen current-induced degradation
IAM SEQUENCE (B-O CID) preconditioning step. LETID test results are most
relevant for identifying hydrogenation state changes in
30%
boron-doped p-PERC and similar PV cells. LETID results are
also used as an input to energy production software models.
27%
25%
25%
20%
Manufacturer (in alphabetical order)
19%
Astronergy
15%
Gstar
55% 57%
• LETID results trended upward on a year-
50%
over-year basis.
45%
• 82% of models tested met LETID high
Percentage of Modules
40%
achiever criteria.
35%
• 0% of models tested returned a LETID red- 30%
flag result.
25%
26%
20%
15%
LETID is a form of module degradation that affects specific
high-efficiency PV cell technologies. For example, boron- 10%
11%
doped p-PERC PV cells require advanced hydrogenation 5%
processes to mitigate extreme boron-oxygen light-induced 1%
0%
3% 3%
degradation (B-O LID), which introduces LETID risks. Gallium- 0–0.5 0.51–1 1.01–1.5 1.51–2 2.01–2.5 ≥2.5
doped p-PERC PV cells, which do not require advanced Power Loss (%)
hydrogenation, are not as susceptible to LETID. LETID risk is
LID HIGH ACHIEVERS
low in n-type PV cell technologies. Cadmium telluride thin- Astronergy, GEP VN, Gstar, JA Solar, JinkoSolar, LONGi Solar,
film devices are not susceptible to LETID. Meyer Burger, Qcells, Runergy, SEG Solar, Silfab Solar, SolarSpace,
Talesun, Trina Solar, VSUN Solar, Waaree, and Yingli Solar met our
LID test category high achiever criteria.
For test category high achiever recognition in the 2024 PV
Module Index Report, RETC required that PV module models
withstand B-O CID plus LETID486 exposure with less than risks. So module designers need to balance B-O LID versus
0.5% degradation in maximum power. At the other end of LETID risk exposure. Cadmium telluride thin-film devices
the spectrum, we considered maximum power degradation and n-type PV cell technologies are not susceptible to LID.
greater than or equal to 2.5% a red-flag result. In this testing
category, we note that 82% of the test samples qualified as For test category high achiever recognition in the 2024 PV
high achievers whereas 0% returned red-flag results. Module Index Report, RETC required that PV module models
withstand the LID sequence with less than or equal to 0.5%
LIGHT-INDUCED DEGRADATION (LID) degradation in maximum power. At the other end of the
The Thresher Test program requires a LID sequence to spectrum, we considered maximum power degradation
investigate a product’s susceptibility to light-induced greater than or equal to 2.5% a red-flag result. In this testing
degradation. LID is a type of degradation resulting from category, we note that 57% of the test samples qualified as
initial exposure to sunlight that impacts some PV cell high achievers whereas 3% returned red-flag results.
types but not others. PV modules that are prone to LID
might experience a relatively rapid rate of performance
degradation over a relatively short time in the field—ranging
from a few hours to a few weeks, depending on the PV cell
LID KEY TAKEAWAYS
technology—before performance stabilizes. This LID test
sequence consists of outdoor light soaking in accordance • 57% of models tested met LID high achiever
with IEC 61215-2. criteria.
20%
low-light performance and bifaciality factor. In this testing
18% category, we note that 65% of the test samples qualified as
15% high achievers.
15%
10%
10%
8% PAN KEY TAKEAWAYS
5%
• 65% of models tested met PAN file high
3% achiever criteria.
0%
0%
<83 83–84 84.1–85 85.1–86 86.1–87 87.1–88 88.1–89 ≥89
• 23% of models tested achieved a >88%
Performance Ratio PR (%)
performance ratio.
PAN FILE HIGH ACHIEVERS
Astronergy, Gstar, JinkoSolar, LONGi Solar, Qcells, Runergy, • 10 different manufacturers were PAN file
SolarSpace, Trina Solar, VSUN Solar, and Yingli Solar met our PAN
high achievers.
file test category high achiever criteria.
Percentage of Modules
call for an elevated cell temperature as compared to
standard test conditions, which results in a lower nominal 20%
power rating.
18%
15%
RETC captures PTC and STC performance data as part of
its CEC testing for manufacturers. A high PTC-to-STC ratio
is of particular interest to project stakeholders as a figure 10% 11%
of merit. Products with a high PTC-to-STC metric generally
utilize cell technologies that experience less power
5%
reduction at elevated temperatures.
4% 4%
40%
38%
35%
Percentage of Modules
30%
25%
23%
20%
15% 17%
TEMPERATURE COEFFICIENT
10%
10% KEY TAKEAWAYS
5% 6% • 27% of models met temperature coefficient
4% 1%
0%
0% high achiever criteria.
<0.21 0.211– 0.241– 0.271– 0.301– 0.331– 0.361– ≥0.39
0.24 0.27 0.30 0.33 0.36 0.39
• 6% of models achieved a temperature
Temperature Coefficient of Power (%/°C Abs)
coefficient ≤0.24%/°C (absolute).
TEMPERATURE COEFFICIENT HIGH ACHIEVERS
Astronergy, JinkoSolar, Meyer Burger, Qcells, REC Solar, Runergy, • 7 manufacturers were temperature
and Silfab Solar met our temperature coefficient test category
coefficient high achievers.
high achiever criteria.
T
Indicators
o meet the expectations of solar project
stakeholders, fielded PV modules and systems must
withstand harsh operating conditions while meeting
or exceeding performance predictions over a 25- to 30- with third-party factory witness BOM verification, RETC’s
year service life. Products and materials that appear very comparative Thresher Test program data helps to ensure
similar on paper may perform, wear out, or break down very that fielded projects meet the expectations of stakeholders
differently under actual conditions of use. A commitment to by empowering them to discriminate between high- and
quality often accounts for these differences. low-quality products.
concept behind our Thresher Test program. Basic IEC and UL Astronergy
certification tests focus primarily on ensuring performance ES Foundry
and safety over the wear-in phase of the product’s lifetime, GEP VN
meaning the first few years of outdoor operation. More Gstar
rigorous testing is required to ensure PV modules can
JA Solar
withstand the expected 25- to 30-year service life implied
JinkoSolar
by modern PV module warranties. The Thresher Test—
LONGi Solar
and the heuristic thresholds applied to its various testing
Qcells
sequences—are intended to identify high-quality module
types and models, much as a thresher machine separates Runergy
In this preliminary June 2024 release of the PV Module Index To achieve RETC’s top honor, module companies had to
Report, RETC has recognized 23 module manufacturers for meet our high achievement criteria in three disciplines:
some form of high achievement across the 14 different testing module reliability, performance, and quality. In other
sequences included within the reliability and performance words, “Overall Highest Achiever” status effectively
disciplines. To capture the results of any remaining long- indicates that RETC recognizes these companies for
duration testing sequences, we will publish a final report “High Achievement in Reliability,” “High Achievement in
release in September 2024. Performance,” and “High Achievement in Quality.” This is
an exceptionally high bar to pass. RETC commends these
To identify top PV module models and manufacturers in our module companies for consistently achieving excellence in
data set, we first evaluated data distributions within specific module manufacturing.
sequences. We then identified thresholds for high achievement
and red-flag results based on engineering best judgment and a Based on a thorough review of these data and results, we
review of scientific literature. Subsequently, we analyzed these have identified nine manufacturers that met our rigorous
summary data and established holistic criteria for recognition, 2024 PV Module Index Report criteria for our “Overall
which are included in this report for transparency. Highest Achiever” recognition.
INDEX
ULE RE
OD
2024
PO
M
PV
RT
HIGHEST ACHIEVER
Representing an extreme downside scenario, one of the Novel technologies tend to degrade in novel ways.
PV module models submitted to RETC for the Thresher Test Collectively, we need to anticipate and test new products
last year returned red-flag results in both a reliability and a and technologies accordingly. As the solar market grows
performance test sequence. Upon further investigation, we in scale and sophistication, industry stakeholders must
learned that these test samples had not come directly out remain vigilant regarding the technical risks inherent to
of a factory but rather had been resold at a discount out of a an accelerated pace of change and the short time frames
warehouse, where they had been stored for an unknown period. between innovation and mass production. As long as the
This double red-flag result is a reminder that the bitterness of solar industry continues to innovate and evolve, there will
poor quality remains long after the sweetness of low price is be a need for data-driven technical due diligence. Caveat
forgotten. If a deal seems too good to be true, it usually is. emptor. Let the buyer beware.
INDEX
ULE RE
OD
2024
PO
M
PV
RT
HIGHEST ACHIEVER
INDEX
ULE RE
OD
2024
PO
M
PV
RT
HIGH ACHIEVEMENT IN
PERFORMANCE
INDEX
ULE RE
OD
2024
PO
M
PV
RT
TEST CATEGORY
HIGH ACHIEVER
I
ndustry analysts expect that the market share for Though it is tempting to view each new cell technology
advanced PV cell technologies—many of which are as an advancement over previous technologies, it is also
already in mass production—will rapidly increase over true that novel cell technologies, especially those based
the next five to ten years. Broadly speaking, these emergent on n-type cell designs, present interesting and unique
PV cell technologies are the result of developments in measurement challenges.
n-type wafer production and progress in surface passivation
and back-contacting methods. These newer technologies Module characterization challenges include the power
include n-type tunnel oxide passivated contact (n-TOPCon), rating of advanced PV devices. There are many factors that
n-type back-contact (n-BC), n-type passivated emitter rear affect the accuracy and uncertainty of power ratings for any
totally diffused (n-PERT), and n-type silicon heterojunction PV module, regardless of cell type. However, equipment
(n-HJT) PV cells. The most mainstream of these novel n-type operators and technicians must adjust their flash-testing
technologies is the n-TOPCon cell. measurement and calibration procedures for advanced PV
cell technologies to accurately measure power. The intent of
In recent years, many module companies have evolved these procedural changes is to address metastability issues,
away from traditional aluminum back surface field spectral mismatch, I-V corrections, device linearity, high
(Al-BSF) technologies to higher efficiency p-type capacitance, and hysteresis. Hysteresis and metastability
passivated emitter rear contact (p-PERC) PV cells. Today, are of particular interest to industry stakeholders, as both
manufacturers are converting p-PERC production lines have the potential to contribute upward of 1%–2% to
into n-TOPCon lines. This is relatively easy to do, as maximum power measurements, which are foundational to
p-PERC and n-TOPCon share many production processes. product benchmarking.
80%
Back contact (p and n-type)
70%
World Market Share
60%
Si-heterojunction (SHJ)
50%
on n-type mono-Si
40%
15%
PERC on p-type mono-Si
10%
S&P ITRPV
5% Global 4%
2024
Data Al-BSF
0%
SPGI2023 2024 2026 2028 2030 2034
Year
Data sources: S&P Global (2023); ITRPV 2024 (2024–2034).
[Link]
2024 PV Module Index Report • © RETC, LLC 2024 • Preliminary SNEC Edition, Published June 2024
Employing thinner solar glass in utility-scale projects can increase stress on the glass, particularly under environmental conditions such as wind or weather fluctuations, leading to higher breakage rates. This increased risk is due to thinner glass not being fully tempered and having fewer defects needed to cause critical flaws. Additionally, as modules become larger with reduced frame profiles, this places further stress on the glass, increasing breakage susceptibility .
The thickness of glass plays a critical role in the tempering process because it affects the temperature differential that can be achieved during heating and cooling. Thicker glass is easier to fully temper as it allows for a significant temperature differential, leading to the necessary stress profile for tempering. With thinner glass, like 2.0-mm thickness, achieving the required temperature differential is challenging without accelerated cooling methods, such as forced air. This limitation makes thinner glass more susceptible to breakage due to less temper-induced stress .
Spontaneous solar glass breakage is closely related to the interaction between module components such as the glass, frame, and mounting rails. As solar glass becomes thinner, the module system must bear more stress, potentially leading to breakage. The term 'big floppy modules' describes a scenario where glass, thinner frames, and closer mounting rails collectively result in higher stress on the glass. This stress increases the likelihood of breakage, suggesting a need for reevaluation of design strategies to ensure the durability of newer, thinner modules .
Manufacturers should balance between minimizing B-O light-induced degradation (LID) and limiting light- and elevated temperature-induced degradation (LETID) in high-efficiency solar cells when considering design. Although advanced hydrogenation processes can mitigate B-O LID in p-PERC cells, it can increase LETID risks. Furthermore, n-type cell technologies like n-TOPCon are more prone to voltage-driven degradation, so the design must carefully weigh these competing degradation processes to ensure long-term reliability .
Laboratory testing for PV modules considers factors like damp heat resistance, potential-induced degradation, and hail durability. These factors are tested through sequences that simulate prolonged exposure to adverse conditions, using parameters like temperature, humidity, and physical impacts to predict how modules might perform in the field. Such testing is crucial for identifying modules that will maintain reliable performance over a 25- or 30-year service life, preventing failures that could arise from environmental stressors not accounted for in less rigorous testing .
Recent studies indicate that spontaneous breakage in solar modules arises from interactions between module glass and structural components like frames and rails. As glass becomes thinner and frames or mounting components reduce or change, the mechanical stability of modules may be compromised, increasing the incidence of breakage. These components' interaction is crucial, as newer, thin-glass modules cannot withstand stresses that were manageable with older, thicker glass designs. Proper alignment and structural compatibility are necessary to avoid stress points that lead to breakage .
PAN files are critical in assessing the bankability of solar projects as they provide a precise characterization of PV module performance, informing energy production estimates through third-party verification. Key drivers of PAN file performance include parameters like low-light performance and bifaciality factors. In simulations, performance parameters derived from PAN files allow investors and developers to make informed decisions regarding project financial viability. High achiever recognition in PAN file testing indicates modules likely to perform well in real-world conditions, enhancing project bankability .
Current testing standards, like the IEC 61215-2, inadequately address severe weather risks because they are based on minimal impact tests that do not account for realistic severe weather events like those found in hail-prone regions. Enhancements suggested include expanding beyond basic tests to include sequences that simulate extreme conditions, such as the Hail Durability Test, which involves impacts of larger ice balls and subsequent stress testing cycles. This approach enables better classification of module resilience and informs product designs that can withstand real-world weather challenges .
Manufacturing thinner glass for solar modules introduces challenges such as increased flexibility, requiring adjustments in handling, pick and place, and rolling equipment. These adjustments may include decreasing the spacing of rollers and suction cups. Additionally, the edges of thinner glass have smaller radii, increasing their susceptibility to impact damage during manufacturing. To mitigate these challenges, manufacturers can employ dedicated cooling equipment for accelerated heat extraction during tempering and design manufacturing processes to accommodate the specific needs of thinner glass .
Specific design adaptations ensure successful solar project deployments by tailoring each project's module and frame specifications to its unique environmental conditions. For example, deploying differentiated products with design approaches that account for site-specific risks such as hail or heavy winds can optimize module longevity and functionality. Adapting designs in this manner avoids using a generic 'solar-as-a-commodity' approach, which might result in suboptimal project performance due to mismatched equipment and environmental challenges .