It’s our goal at Voltaic Systems to provide the highest quality, small scale solar panels to our customers. Should one of our existing small solar panels not fit your needs, here is our guide to making a custom solar panel.

For more information, contact us at (212) 401-1192 or better yet, schedule a consultation with a Voltaic expert.

What is the solar panel development process?

Voltaic solar panels have a track record of thriving in almost any environment, 24x7, 365 days a year. Our panels have been bobbing in the saltwater of the Indian Ocean, mounted on huts in the deserts of Africa, and braved the snow and altitude in the Himalayan Mountains.

Here's what you get when you choose Voltaic custom solar panels:

  • Panels designed to last 10+ years in production environments
  • Construction using the highest quality materials
  • High-efficiency photovoltaic cells
  • Designers with years of experience meeting demanding solar specifications

What is the solar panel development process?
  1. Exploratory Discussion - Typically a combination of phone and email conversation so we can learn about your project specifications and timeline
  2. Panel Specifications and Design* - You will help us specify voltage, power, dimensions, materials and mounting mechanism and we will provide one or more designs that meet your requirements.
  3. Prototype
  4. Full production

*To determine the panel specifications, we typically need to know:

  • Power consumption per day and peak power requirements of the device to be charged
  • Geographic conditions of field use
  • Any physical constraints
  • Voltage, capacity and chemistry of battery you expect to use and desired charge time

What power and voltage options do I have?

Total power is determined by surface area. We use 19% efficient monocrystalline cells which provide about 0.019 Watts per square centimeter or 0.12 Watts per square inch. For example the solar cell sections on this 2.2 Watt panel measures approximately 4in x 4.8in, adding up to 2.2W.

power density monocrystalline cells

As a general rule of thumb, we typically recommend that the voltage of the solar panel is 1.5 times the voltage of the battery. This ensures efficient charging throughout the charge cycle.

Recommended Panel Voltage

Battery VoltagePanel Voltage
3.7-4.2V 6V
7.2-8.4V 12V
10.9-12.6V 18V

We create a specific voltage by stringing individual cell pieces in series. Each cell piece is ~0.5 Volts, so for the 2.2W panel shown below we used 12 pieces to create a 6 Volt panel.

string cells in series solar panel

What chemistry cells do you use?

We typically use mono-crystalline cells for their high efficiency (19%). We can use other cells including CIGs if that is what your project requires.

What are the coating options?

All solar cells are protected with some sort of coating material. For commercial solar panels, it is often glass. For smaller panels there are a number of different options.

Urethane: Highly UV resistant, but heavier than ETFE. Our standard panels have a urethane coating and last up to 10 years in the sun with minimal power degradation. The urethane coating is poured or "potted" on the solar cells and leads to a highly waterproof panel.

ETFE: Slightly less UV resistance than urethane, but lighter weight. ETFE is attached to the cells via a lamination process. Finish available in glossy or matte.

Epoxy or PET: We don't recommend this coating as it tends to have a relatively short lifetime. It is the least UV resistant of any of the options.

Glass: Most UV resistant, but also the heaviest and can be challenging to mount in a streamlined manner.

The left images shows a) aluminum-plastic-aluminum substrate with urethane coating b) PCB substrate with ETFE coating and c) aluminum substrate with glass coating. The right image shows matte vs glossy ETFE coating.

urethane vs ETFE vs glass coated solar panels
solar panels with matte vs glossy coating

What are the substrate options?

The solar cells are mounted on a substrate or backing. Again, there are several options.

Aluminum-Plastic-Aluminum: Very high strength to weight ratio material used in commercial building applications. Easy to create waterproof panel. Allows embedding of screw or nut into substrate.

PCB Plastic: Different thicknesses available, from 1mm to 5mm depending on requirements. Allows embedding of knurled nut into substrate. Higher density than Aluminum-Plastic-Aluminum substrate. Not waterproof without additional hardware.

Aluminum: Typically the strongest substrate option, but is also the heaviest. Thin and rigid.

What mechanical mounting features are available?

Depending on the substrate material used, we can embed screws or nuts into the panel, leave empty through-holes or simply flat backs.

mounting options on back of solar panels

What type of wire is used?

Our standard wire has strain relief is about 12 inches long and terminates in a 3.5x1.1mm plug. This can be changed to whatever length and terminal you prefer. The wire can be embedded into the substrate to keep it waterproof or soldered on the outside of the panel. Power and ground wires can even be separated as shown below.

wire connection on back of solar panel

Are there any design or tooling fees?

There are no design fees to create a prototype of your custom solar panel. Some, but not all designs may require a fee to prepare the machinery to create your specific panel at volume. This tooling fee begins at around $1,000.

Is there a minimum order quantity or MOQ?

Our MOQ is typically 1,000 panels although we can sometimes lower this number for minor changes to existing solar panels.

Any useful tips that you can offer in advance?
  1. Reduce your circuit’s power requirements before discussing the panel’s power requirement. For example, if you can reduce your circuit’s mA requirements by 50% this reduces the size of the solar panel by 50%, saving you money, size, and weight.
  2. Prototype your project with solar panels we already manufacture before moving forward with custom designs. We have circuit boxes that allow you to sum the panel power in parallel or series to increase the current or voltage, so you can approximate how the custom panel will perform.

Can I consult with a Voltaic solar panel expert?

Yes, please fill out this form so that we can help and someone will contact you within one business day.