With many different types of IoT devices and low-power electronics, we don’t always have a standard design that meets customer’s needs. Luckily, we produce custom panels built to your specific requirements.
During this stage, PowerFilm works with the customer to go over everything the solution may need electrically and mechanically.
The next step is to use all requirements and information gathered during concept development to create and propose a solar solution.
During this phase, we define all relevant panel characteristics that meet your unique application needs, including size, shape, PV technology, flexibility, substrate, mounting mechanism, wiring, connectors, contacts, electronics, weatherproofing, surface finish, aesthetics, testing, and more.
This process generally takes the form of a 2D CAD drawing of the panel concept with defined electrical and mechanical specifications.
Design proposals include prototype and production pricing and any engineering time required for the project.
You can review, ask questions, and offer changes or modifications until you are satisfied with the design proposal.
*Photo courtesy of Plastic Logic
After approving the design proposal, PowerFilm engineers begin building and assembling functional prototypes.
Depending on the design, prototypes may be ‘built by hand’ and not look exactly like the production unit. Changes between prototype and volume production are clearly defined in the product proposal.
Prototype assembly usually takes 2-3 weeks for simple builds but could take longer for more intricate designs or custom materials.
With functional prototypes complete, testing in the application environment is critical in determining a solar solution’s performance.
Things to test and verify include:
Adequate power generation under expected and variable conditions
Ease of installation
Viability of weatherproofing (if required)
Power consumption of the end device
Mechanical stability and function
Pilot production allows us to refine the manufacturing of your specific design and prepare for volume production.
During this stage, we test and tweak new equipment, jigging, and processes related to the solar design.
Larger scale field testing is incorporated into this step, which can catch and resolve variation issues before launching the product at scale.
Volume production is the last step in the design process, but innovation always continues.
Once your solar solution enters production volume, we refine our processes to manufacture solutions better and more efficiently.
We provide the best possible solutions for our customer’s needs. As we expand our technical capabilities, we continue working with customers on next-generation products and enhancements to current designs.