Custom Flexible Solar Panels for Curved Surfaces & Lightweight Builds

Standard rigid modules are built for flat, open roofs. Many real projects are not:

• Roofs are arched or ribbed on vans, RVs and trailers
  
• Gelcoat decks on boats are sensitive to holes and heavy frames
  
• Weight is critical for mobile and off-road platforms
  
• Space is broken up by hatches, vents and antenna mounts
  

Custom flexible panels help you:

• Follow the curve of your surface and reduce wind noise
  
• Keep weight and profile low for better aerodynamics
  
• Use adhesive or low-profile mounts instead of large brackets
  
• Fill odd-shaped or narrow spaces with usable solar area

Our custom flexible modules are engineered to work where framed modules are difficult or risky:

• Curved roofs – campervans, buses, coach roofs, expedition trucks
  
• Marine decks – yachts, sailing boats, catamarans and workboats
  
• Thin roofs and skins – lightweight trailers and specialty enclosures
  
• Removable or temporary installations – demo units, rental fleets, show vehicles
  

We work from your photos and CAD drawings to define safe bend radius, mounting zones and cable routing before any tooling is cut.

Every environment is different. You can specify materials that match your durability and cost targets:

• ETFE front sheet
  High UV resistance and anti-soiling surface
  Recommended for marine and long-term outdoor use
  
• PET front sheet
  Cost-effective choice for lighter duty or intermittent outdoor use
  Suitable for shaded or partially protected areas
  
• Thin-glass or hybrid laminates (optional)
  Extra scratch resistance with controlled weight
  Use when foot traffic or abrasion is expected
  
• Backsheet and encapsulation
  White or black backsheet options
  Encapsulation tuned for adhesion, flexibility and operating temperature
  
• Junction box & cabling
  Low-profile junction boxes with sealed entries
  UV-resistant cables, strain relief and waterproof connectors
  

All modules are built under controlled processes with IV testing and visual inspection before shipment.

We treat each flexible module as part of your system, not a generic commodity. Key parameters you can define include:

• Size & shape
  Panel length and width to the millimetre
  Rectangular, tapered or contour-matched outlines
  
• Electrical performance
  Target voltage (e.g. 12 V, 24 V, 36 V or custom Vmp)
  Power rating (from tens to hundreds of watts)
  String layout and bypass diode strategy to handle partial shade
  
• Cable & connector configuration
  MC4, SAE, Anderson or custom connectors
  Cable gauge and length to match your system layout
  Exit location (front, rear, side) and orientation
  
• Mounting approach
  Adhesive-ready backsheets
  Grommet holes or low-profile mounting strips
  Edge design to interface with your chosen hardware
  
• Branding & identification
  Your logo on the laminate or label
  Custom part numbers and serialisation for traceability
  Packaging and documentation with your brand name

A successful flexible installation is more than “stick it down and forget it”. When you plan your design, consider:

• Bend radius
  Each laminate has a minimum bend radius; provide roof curvature data so we can design a safe stack-up.
  
• Surface preparation
  Surfaces should be clean, dry and compatible with the adhesive or tape system you plan to use.
  We can recommend suitable adhesive types based on your substrate.
  
• Thermal expansion
  Allow for expansion and contraction across the panel length and width.
  Avoid trapping edges rigidly on all sides to reduce peel stresses.
  
• Cable routing & protection
  Use waterproof cable glands and drip loops for roof entries.
  Provide mechanical protection where cables pass near sharp edges or moving parts.
  
• Inspection & maintenance
  Design access so panels can be visually inspected over time.
  Consider how panels could be removed or replaced if required in the future.
  

This planning up front increases service life and reduces field issues.