Custom Solar Engineering

We engineer solar solutions tailored to system constraints, not standard formats.

Start a Custom Design

System requirements define geometry, electrical architecture, and environmental durability. We engineer each solution to meet those constraints from concept through production.

When Custom Engineering is Required

Standard panels serve standardized applications.

Custom engineering becomes necessary when system constraints eliminate those options.

  • Constrained form factor: Fixed footprint, curvature, low-profile, or non-rectangular geometry.

  • Defined electrical targets: Voltage, current, and battery interface alignment.

  • Environmental exposure is severe: Vibration, thermal cycling, moisture, and impact conditions.

  • Weight or thickness is limited: Portable, mobile, or embedded platforms.

  • Lifecycle control is required: Long-term programs with revision tracking and repeatable production.

We engineer to requirements, not catalog limitations.

What We Engineer

We control the mechanical, electrical, and environmental architecture of every design.

Geometry & Mechanical Integration

  • Custom form factors and substrate selection.

  • Mounting interface design and structural alignment.

Electrical Architecture

  • Defined voltage and current targets

  • Series/parallel configuration and load matching

  • Power conditioning compatibility

Environmental Design

  • Encapsulation strategy

  • Thermal cycling tolerance

  • Moisture and vibration resistance 

Proven Engineering Partnerships
We first conceived our Sol-Lux Eos solar-powered, autonomous window awning over 10 years ago. At that time, we were fortunate enough to identify PowerFilm as the nation’s leading manufacturer of flexible solar panels. We began the design dialog, received samples, and confirmed our ideas were viable. This kept the dream alive and once our parent company, Carefree of Colorado was in a position to strike, we picked up where we left off and PowerFilm was ready to help. Their capable engineering staff worked closely with Sol-Lux to deliver a custom solar solution that meets our needs exactly.
Mark Goth
Sol-Lux
PowerFilm was a great partner when we developed our remote monitoring system. Their design team was very creative and energetic and really listened to our requirements when building our prototypes. From our first consultation through to our first volume order, the PowerFilm team was responsive and attentive. We enjoy doing business with PowerFilm and recommend them to anyone who needs remote or portable power.
Bill Bertuleit
Research & Development ASG, Airgas
PowerFilm Solar was an asset during the development stages of our Ellipse smart bike lock. Customers were impressed by the flexibility of the panels, which allow for a unique industrial design that could not be accomplished with rigid crystalline panels. PowerFilm Solar was able to support our prototyping needs creating customizations that we needed at the various stages of the project. The Ellipse is a new take on bike locks, and PowerFilm Solar helped make it a reality.
Jeremy Ricard
Lattis

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