Manufacturing Process of Aluminium Solar Panels

Solar energy is at the forefront of a global transition towards sustainable energy. With increasing demand comes an increasing focus on solar panel performance as well as factors affecting their longevity and overall price. What is one key factor? - Aluminium.

Aluminium is light, corrosion resistant, and easily fabricated, providing an essential role in supporting both the solar panels and their structures! But what is the precise manufacturing process that converts aluminium from a raw material into the stylish subframe you see on rooftops and solar farms? In this article, we are going to break it down step-by-step and in as generic a way as possible without any industry specific jargon.

Why do we use Aluminium for Solar Panels?

Before we start the process, let's briefly discuss why aluminium is very commonly used in solar panels:

• Lightweight: Very portable, simple to set up, and easy to work with

• Corrosion Resistant: Outside panels exposed to changing weather conditions must be corrosion-resistant.

• Product strength-to-weight ratio: Robust and long-lasting without excess bulk

• 100% Recyclable: An eco-friendly choice that is completely recyclable

We can now go on to the manufacturing process itself because it is out of the way.

Manufacturing Process of Aluminium Solar Panels

Manufacturing of the aluminum solar panel consists of a few steps. Let’s walk you through each step.

Step 1: Extracting and Refining Aluminium

This entire process starts with bauxite ore, which is full of aluminium. Bauxite goes through a refining process called the Bayer Process, and is changed into alumina (Aluminium oxide). Here is the Bayer process:

• The bauxite is crushed and mixed with sodium hydroxide.

• Then it is heated under pressure. The aluminium dissolves, and separates from the sediment.

• The solution is cooled and alumina forms out of it.

• Alumina is filtered, washed and heated again to remove moisture.

• This leaves us with a white powdery substance for pure alumina.

Step 2: Smelting into Aluminium Ingots

The next step is to convert alumina into pure aluminium metal through a process called electrolysis, specifically the Hall-Héroult Process.

• Alumina is dissolved in molten cryolite in an electrolytic cell.

• Electric current passes through this mix; breaking the bonds in alumina.

• Aluminium is settled at the bottom and oxygen is released.

• The molten aluminium is poured into molds to make ingots - which are foundations of aluminium metal that will be processed.

Step 3: Rolling and Forming

Now that we have ingots of aluminium, they're ready to be rolled into thin sheets or extruded as is (e.g. L- or U-section rails that are typical in solar panel frames). There are two pathways here:

a) Rolling into Sheets (used for back sheets or some of the frame parts).

• The ingot is heated, then goes through heavy rollers multiple times.

• Eventually, the ingot is flattened into uniform, thin sheets of the correct thickness.

• The sheets are then cooled and trimmed.

b) Extrusion for Frames.

• The ingot is heated, and then forced through a die (a tool that changes the shape of material).

• It comes out in continuous profiles, think of long aluminium rods produced in shapes.

• The profiles go through various cooling and straightening before they're cut to standard lengths.

• At this stage, aluminium starts to resemble parts that we see on solar panels.

Step 4: Surface Treatment.

Since aluminium will be subjected to sun, wind, rain, and sometimes salt (if located in coastal scenery), a little bit of protection is needed. This is where surface treatment comes in. Surface treatment is generally:

Anodizing: A controlled oxidation process that produces corrosion resistance. Anodizing also allows for color.

• Powder Coating: Thicker layer, and decorative/protective.

• Brushed or sanded: For appearance and to remove slight surface imperfections.

• These treatments make sure the aluminium won’t rust, pit, or corrode easily over time.

Step 5: Precision Cutting and Drilling

Next up: cutting and drilling. Solar panel frames need to fit perfectly, no loose ends, no misalignments.

• Automated machines cut the aluminium profiles to exact measurements.

• Holes are drilled for screws, bolts, and mounting hardware.

• Corners are often notched to allow for smooth assembly.

At this stage, each aluminium piece is custom-prepped based on the panel design it will support.

Step 6: Assembly of the Frame

Time to bring it all together.

• The aluminium pieces are joined, usually with brackets, screws, or corner keys.

• A square or rectangular frame is formed, matching the dimensions of the solar panel.

• Rubber gaskets or insulation may be added where the solar panel glass will sit.

This frame not only protects the panel’s edges but also provides the base for mounting on rooftops or ground structures.

Step 7: Integrating with the Solar Panel

The frame is now attached to the solar panel itself:

• The glass layer (top), solar cells, and backsheet (bottom) are laminated together.

• This laminate is then fitted snugly into the aluminium frame.

• Sealants are applied to prevent water ingress and to ensure long-term durability.

Some panels use additional aluminium sheets on the backside for added strength and heat dissipation.

Step 8: Quality Check & Packaging

Every panel undergoes strict quality testing:

• Visual inspection for dents, scratches, or frame defects.

• Load tests to ensure the frame can handle stress (wind, snow, etc.).

• Fit-checks to make sure mounting components align correctly.

Once passed, the finished aluminium-framed solar panels are packaged, usually in protective foam and crates, and shipped out to warehouses or directly to installation sites.

Conclusion

The manufacturing process of aluminium solar panels combines heavy industry with high precision. From mining bauxite to delivering a perfectly framed panel, every step counts in ensuring durability, efficiency, and long-term performance.

So next time you see a solar panel, remember, it’s not just about the silicon cells. It’s also about the silent workhorse holding it all together: aluminium.

Disclaimer: This content is sponsored and does not reflect the views or opinions of Ground Report. No journalist is involved in creating sponsored material and it does not imply any endorsement by the editorial team. Ground Report Digital LLP. takes no responsibility for the content that appears in sponsored articles and the consequences thereof, directly, indirectly or in any manner. Viewer discretion is advised.

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