Custom Solar Panels: Powering Your Innovation

At LinkSolar, we specialize in designing and manufacturing custom solar panels tailored precisely to your product's unique requirements. Whether you're developing cutting-edge IoT devices, robust industrial sensors, portable electronics, or any application needing reliable, independent power, we provide bespoke solar solutions that integrate seamlessly. We partner with you to transform your concepts into high-performance, durable solar modules built for the real world.

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Our Collaborative Development Process

We believe in a transparent and collaborative approach to bring your custom solar panel vision to life. Our typical process involves four key stages:

1. Initial Consultation & Discovery: We start with in-depth discussions (phone, email) to fully understand your project goals, technical specifications, power requirements, operating environment, desired quantities, and timelines.
2. Design & Specification: Based on our consultation, our engineering team develops detailed panel drawings. These include critical parameters like dimensions, mounting features, solar panel efficiency targets, voltage/power output, material selection (cells, coating, substrate), wiring, and connector types. We iterate with you until the design is perfected.
3. Prototyping & Validation: We manufacture functional solar panel prototypes based on the approved design. These samples allow you to test and validate performance, durability, and integration with your device against your specific criteria and real-world conditions.
4. Volume Production & Logistics: Once samples are qualified, we move to full-scale manufacturing. Our rigorous quality assurance processes ensure consistency and reliability. We manage the entire production and can handle logistics, including import processes or direct shipment to your contract manufacturer (CM).

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Quality Assurance & Performance Standards

Reliability is paramount. Our custom solar panels are built using materials and processes designed for longevity and resilience. Depending on the final configuration, the core material stacks we utilize have often undergone rigorous testing, including:

• Accelerated Environmental Testing (Combined Heat, Humidity, UV exposure)
• Thermal Cycling Stress Tests
• Damp Heat Endurance Testing
• Mechanical Shock and Vibration Resistance
• Impact Resistance Testing
• Chemical, Oil, and Saltwater Exposure Resistance

Contact us to discuss the specific qualification data relevant to your chosen panel construction.

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Tailored Power & Voltage Options

The power output of your custom panel is primarily determined by the total active solar cell area and the efficiency of the cells used. We work with various high-performance cell technologies, including:

• Standard Monocrystalline Solar Cells: A reliable and cost-effective option offering excellent performance.
• High-Efficiency Back-Contact Cells (e.g., SunPower): Offering premium efficiency (more power per unit area), superior performance in partial shading, enhanced durability due to robust copper backing, and a sleek, uniform appearance. Ideal for space-constrained applications.

	Cell	Type	Dimensions (mm)	Power (Watts)	Efficiency(%)
		monocrystalline
	SunPower Maxeon Gen 3	n-type, monocrystalline, Back-Contact	125 x 125	3.72	24%
	SunPower Maxeon Gen 6	n-type, monocrystalline, Back-Contact	166 x 166	6.71	24.5%

 

We precisely cut these cells into custom shapes and sizes using laser technology and assemble them to maximize the power output within your available surface area.

• Voltage Customization (Series Connection): We primarily achieve the target voltage by connecting the required number of individual cell pieces in series. Using high-efficiency SunPower cells as an example, the typical voltage per cell is approximately 0.6V. Therefore, connecting 12 SunPower cells in series results in a cell group (or string) with a nominal voltage of approximately 7.2V. Series connection adds up the voltage of individual cells, while the current remains largely unchanged (approximately equal to the current of a single cell).

• Current Enhancement (Parallel Connection): In solar panel design, parallel connection is just as important as series connection. When it's necessary to increase the panel's total output current, we connect multiple individual cells or multiple pre-connected series strings in parallel. Parallel connection adds up the current from each branch (individual cell or string), while the voltage remains largely unchanged (approximately equal to the voltage of a single branch).

Optimizing for Lower Voltage: Where feasible for your circuit design, we often recommend specifying the lowest operational voltage possible. Benefits include:

• Higher Current: For the same panel area, a lower voltage panel delivers higher current. If your circuit doesn't need the extra voltage, opting for lower voltage/higher current can result in more usable power.
• Improved Area Efficiency: Fewer cell connections mean less "dead space" lost to inter-cell gaps, maximizing the active power-generating area.
• Better Shade Tolerance: Higher voltage panels with more, smaller cell pieces can be more susceptible to power loss from partial shading or soiling.
• Potential Cost Savings: Fewer pieces and connections can sometimes translate to slightly lower manufacturing complexity and cost.

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Protective Coating Choices

The top coating protects the solar cells and determines the panel's durability, environmental resistance, and aesthetics. We offer several options to match your needs:

• ETFE (Ethylene Tetrafluoroethylene): Our most popular choice. Lightweight, highly transparent, UV resistant, waterproof, and cost-effective. Offers excellent durability with an expected outdoor lifetime of 7+ years when using high-quality materials. Ideal for many OEM solar panels and IoT solar panels.
• Glass: Offers superior scratch resistance, excellent UV stability, and potentially the longest lifetime (10-15+ years), especially when integrated into a frame. It is, however, the heaviest option and more rigid.
• Urethane (Potting): Creates a highly durable, waterproof, and UV-resistant panel by fully encapsulating the cells. Offers excellent protection in harsh environments and a potential lifetime of 10+ years. Adds some weight and thickness compared to ETFE.

*Actual lifetime depends on design, materials, environment, and operating conditions.

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Durable Substrate Materials

The substrate provides the structural backing for the solar cells. Common solar panel substrate options include:

• PCB (Printed Circuit Board): Highly versatile, available in various thicknesses (0.6mm - 3mm). Offers excellent rigidity and integration potential for electrical connections. Can be single-sided, double-sided, or FR4 (no copper). Our most common substrate.
• Aluminum Composite: Used in specific applications (like our urethane panels), offering a very high strength-to-weight ratio and allowing for embedded mounting hardware.

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Advanced Assembly Techniques

We connect the solar cell pieces using methods optimized for performance and panel size:

• Traditional Cell Stringing: Soldering ribbon connects the front of one cell piece to the back of the next. Suitable for many panel sizes and designs.
• SMT (Surface Mount Technology): Primarily used with back-contact cells. Cells are placed onto a custom PCB with solder paste and reflowed in an oven. This allows for more intricate layouts, smaller cell pieces, and is often preferred for small solar panels (e.g., under 1 Watt) or complex shapes.

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Flexible Mounting Solutions

Securely integrating the panel into your product is crucial. We offer various custom solar panel mounting options:

• Through-Holes: Standard mounting holes placed according to your specifications.
• Embedded Fasteners: Screws or threaded inserts integrated directly into the panel substrate (often with PCB or Aluminum).
• Adhesives: High-bond adhesive tapes (like VHB) for direct surface mounting.
• Custom Brackets & Enclosures: We can design and supply custom mounting brackets, frames, or gaskets to meet specific integration challenges.

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Connection & Wiring Customization

We provide flexible options for electrical output:

• Solder Pads: Located on the back (typically with PCB substrates), often ENIG coated for reliable soldering. Placement can be customized.
• Wires & Connectors: Specify wire gauge, length, color, and termination (stripped ends, specific connectors).
• Waterproofing & Strain Relief: For outdoor applications, connections are typically sealed using robust junction boxes, silicone potting, or overmolding for connectors, ensuring IP-rated protection and cable strain relief.

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Customized Solar Panel Example

 

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Design Support & Tooling Fees

• Design: We do not charge fees for creating initial solar panel design drawings and specifications.
• Tooling: Most custom panel designs do not require specific tooling fees. Exceptions may apply for highly custom injection molded parts (like unique junction boxes or frames) or specialized fixtures, which would be clearly quoted upfront.

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Minimum Order Quantities (MOQ)

Our manufacturing process is optimized for volume production. Typical MOQ solar panels start around 300 - 1,000 units, depending on the panel size, complexity, and chosen materials. Please discuss your volume requirements with us.

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Logistics & Supply Chain Management

We understand the complexities of global supply chains. We can assist in selecting manufacturing locations and materials to optimize logistics and potentially mitigate import duties or tariffs, depending on your final market and assembly location. 

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Getting Started with Your Custom Solar Panel

Ready to explore a custom solar solution?

1. Estimate Power Needs: Analyze your device's power consumption, especially in worst-case conditions (low light, temperature extremes). Consider the target operating location's solar irradiance.
2. Optimize Device Efficiency: Reducing your device's power draw is often the most cost-effective way to reduce required panel size, weight, and cost.
3. Prototype Early: Use off-the-shelf panels or our rapid prototyping service to validate your power budget and circuit design before committing to full custom tooling or volume.

Contact us today to start the conversation about your custom solar panel needs. Let our experts help you design the perfect power solution for your product.