Design Options

PowerFilm can customize many aspects of a solar panel including PV technology, electrical connections (integration of charge controller integration, bare wires, many types of connectors, flexible printed circuit connectors, PCB thru-holes), mounting options (pressure-sensitive adhesives, mechanical fasteners, direct lamination to your surface, front or backside contacts), encapsulation (waterproofing, UV protection,  surface finish, aesthetics, abrasion resistance), panel shape, panel size, substrates (plastic, fiberglass, metal, fabric, vinyl, glass), test to your requirements, and more.

small amorphous silicon thin film solar panel with wire connections
solar panel connected to a pcb using backside contacts

Connections and Mounting

A solar panel has to integrate electrically and mechanically with the rest of a system. This will look much different for a smaller panel powering an IoT sensor than for a large panel installed on a truck.


PowerFilm provides many options for connecting and mounting panels to fit the diverse needs of the industries we serve. 

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water bouncing off a thin-film amorphous silicon solar panel


Protective laminates and other encapsulants are needed to protect the bare solar material, which is prone to scratching and corrosion. Laminate encapsulation can also provide excellent water and weatherproofing to a solar panel. 


PowerFilm offers a wide variety of lamination and encapsulation options to meet the diverse needs of the industries we serve. 

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small thin-film amorphous silicon solar panel with tabs

Panel Shape

PowerFilm can manufacture solar panels that are very small, less than a square inch, and large arrays that power base stations. Although the active solar area is typically rectangular, the substrate and material around the panel can be cut into irregular shapes, including fold-over tabs and notches. 


Use the Custom Solar Panel Design Tool to see the different sizing options for Electronic Component Panels, which can also be combined to form larger arrays.

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thin-film amorphous silicon solar panel on a fabric substrate


PowerFilm can adhere solar material to many different surfaces, including plastic, fiberglass, metal, fabric, vinyl, and glass. 

Some reasons to use a substrate include increasing rigidity, adding mounting hardware, or combining component panels into an array.  

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