How is PowerFilm made?
PowerFilm is manufactured using an internally developed, proprietary manufacturing processes. The core process is a true roll-to-roll process. The general process steps are Vacuum Deposition (Back Metal, Amorphous Silicon, Transparent Top Contact), Printing and Laser Scribing, Bus Bar/Lead Attachment, Encapsulation, and Die Cutting. PowerFilm is patterned on a 13 inch wide web on a roll up to 2400 feet long.
In April, 2015, PowerFilm's production process was featured on The Science Channel / Discovery Channel in an episode of the popular TV show "How It's Made". To learn more about how thin-film foldable solar panels are manufactured check out the episode.