Development Process

A structured engineering process from defined requirements to validated volume production.

Start a Custom Design

We begin with defined electrical and environmental requirements. Each phase validates performance before progressing to scale.

 

Concept Development

We begin with defined power requirements and deployment constraints. Load profile, duty cycle, temperature exposure, installation environment, and system budget establish design boundaries.

We typically start with proven product families before advancing to custom configurations.

PV technology, electrical architecture, mounting method, encapsulation, and integration strategy are selected based on performance and durability requirements.

Design Review

Defined requirements are translated into a documented design proposal, including 2D CAD drawings and electrical and mechanical specifications.

Technical direction is confirmed prior to build. Prototype and volume pricing are aligned with non-recurring engineering (NRE) requirements.

This phase establishes architecture control and production readiness.

Prototype

Functional prototype units are assembled to validate electrical output, mechanical integration, and environmental performance.

Builds confirm dimensional fit, interconnect configuration, and interface compatibility. Deviations between prototype and intended production configuration are documented and reviewed prior to release.

Testing verifies performance under defined load conditions before pilot production.

Prototype timelines typically range from 2–3 weeks for defined configurations, with additional time required for complex integrations.

Field Testing

Application-level testing validates system performance under real operating conditions.

Deployments verify electrical output against defined load profiles and confirm behavior under variable environmental exposure. Installation procedures, mounting integrity, and interface reliability are assessed in representative use scenarios.

Testing confirms:

  • Power generation under variable conditions: Verified against defined load requirements.

  • Installation repeatability:  Evaluated for consistency and field practicality.

  • Environmental durability: Assessed under moisture, temperature, and UV exposure.

  • Thermal stability: Validated across specified operating ranges.

  • Mechanical integrity: Confirmed under vibration, handling, and in-service conditions.

Pilot Production

Pilot production validates manufacturing readiness and confirms repeatability prior to controlled release.

Process parameters are established. Tooling and fixtures are validated. Assembly repeatability is confirmed. Equipment settings, material handling procedures, and inspection criteria are documented under real production conditions.

Larger-scale builds evaluate yield, cycle time, and quality consistency.

Process variation is identified and controlled before full release.

Volume Production

Following successful pilot validation, production transitions to controlled volume manufacturing.

Material specifications, equipment settings, assembly procedures, and inspection criteria are formally documented. Quality controls ensure repeatability across batches and long-term production runs.

Ongoing manufacturing includes process monitoring, yield tracking, and controlled refinement of assembly parameters.

Volume production operates under documented quality control and lifecycle support.

Engineering Evaluation

Provide power and integration requirements for review.

Submit Project Requirements