How PowerFilm Helped GEM Build a Better Solar Solution for Their Low-Speed Electric Vehicles

Posted on 10/01/2025 at 01:31 by Seth Hansen

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Blue GEM low-speed electric vehicle parked in front of an industrial building, with overlaid text stating, "How PowerFilm Helped GEM Build a Better Solar Solution for Their Low-Speed Electric Vehicles."
Originally Published 4-27-2023

Powering the Future of Sustainable Fleet Transportation

A blue GEM low-speed electric vehicle drives down a suburban street with several smiling passengers inside, passing modern houses and greenery under a cloudy sky.

Fleet operators are always looking for ways to reduce downtime, control energy costs, and improve sustainability in electric vehicle fleet operations. GEM's low-speed electric vehicles (LSEVs) are already a smart solution for campuses, resorts, and business parks—but what if they could do even more?

That’s where solar comes in. Working with PowerFilm, GEM developed a powerful, custom solar upgrade that helps fleet managers extend range, minimize reliance on charging infrastructure, and visibly demonstrate their commitment to clean energy.

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The Challenge: Solar Charging for Commercial Electric Vehicles

A person wearing a brown jacket and work gloves plugs a charging cable into the front of a white GEM low-speed electric vehicle, with a brick wall in the background.

GEM vehicles often operate in environments where traditional charging infrastructure is sparse or inconvenient. Between frequent stops and long hours parked outdoors, these vehicles were prime candidates for solar charging—but only if the system could meet the demands of commercial operations.

GEM needed a solar partner who could design a solution for low-speed electric vehicles that was powerful, easy to integrate, and scalable across their lineup.

Why GEM Chose PowerFilm as Their Solar Partner

Graphic titled "Why GEM Chose PowerFilm" with icons and text highlighting Solar Expertise (35+ years), Custom Design Capabilities, and Speed to Market (rapid prototyping and production), centered around a handshake illustration.

GEM wasn't looking for an off-the-shelf solar panel. They wanted a partner who could:

Engineer a high-efficiency, vehicle-specific solar solution
Deliver volume production quickly and reliably
Ensure easy installation and long-term durability for commercial fleets

PowerFilm met every requirement. With over 35 years of solar innovation and a reputation for rapid prototyping, we were ready to deliver.

“GEM has been committed to clean mobility for over two decades. Partnering with PowerFilm allowed us to bring that commitment to life through smart, renewable charging.”
— Sven Etzelsberger, Director of Engineering, Waev (GEM’s parent company)

Designing a Custom Solar Kit for GEM Low-Speed Electric Vehicles

Top-down view of a black GEM low-speed electric vehicle equipped with PowerFilm solar panels covering the roof. A circular diagram showing six stages of a product development cycle: Concept Development, Design Review, Prototype, Field Testing, Pilot Production, and Volume Production. Each stage is represented by a colored circle with directional arrows connecting them in sequence.

Our collaboration began with hands-on prototyping. PowerFilm received a GEM e4 vehicle to test and develop a solar charging system tailored to GEM’s specific design.

How do we go from prototype to production-ready? Read about our custom solar design process.

After several design iterations, we created a modular solar kit built around 120W Maxeon solar panels.

The Custom Solar Design Process

Comparison graphic showing Maxeon solar panels with 24.3% efficiency outperforming standard solar panels with 19–21% efficiency. Maxeon panel is illustrated in dark blue with a sun and lightning bolt icon above, while the standard panel is shown in light gray.

Each panel features Maxeon’s high-efficiency back-contact solar cells, delivering reliable, high-performance solar power for commercial electric vehicles.

They include:

UV- and heat-resistant ETFE lamination for durability
Lightweight fiberglass construction to minimize vehicle weight
Automotive-grade, custom-length wrapped cabling for easy installation

Learn more about why we use Maxeon's high-performance solar cells.

Quote from Brad Scandrett, PowerFilm's VP of Engineering, about how aligned engineering enabled GEM's custom solution to go from prototype to production in under a year.

The scalable design includes:

Two 120W panels (240W total) for GEM e4 vehicles
Three 120W panels (360W total) for GEM e6 and eLXD models

Commercial-Grade Integration and Durability

Close-up view of a blue GEM low-speed electric vehicle with a PowerFilm custom rooftop solar panel installed.

Built specifically for fleet operators, this solar solution includes:

A sleek, black anodized frame that slots into GEM’s existing roof rails
Pre-engineered mounting holes for clean, secure installation—no drilling required
A custom front guard for a polished, OEM-grade appearance
Compatibility with both AGM and Li-ion batteries
Seamless operation with standard 1kW or fast chargers—no need to disconnect solar

GEM Solar Panel Benefits

Maintenance is minimal. Thanks to the ETFE surface, panels naturally shed dust and dirt with rain or an occasional wipe-down.

Benefits of Solar-Powered GEM Vehicles

Graphic showing "Additional Range Per Day: 4.3 – 12.4 miles" inside a blue arc.

Extended range: Gain 4.3 to 12.4 miles of solar-powered range per day

Lower charging costs: Reduce reliance on grid power

Increased uptime: Charge passively while vehicles are parked

Operational efficiency: Minimize time spent rotating and plugging in vehicles

Sustainability visibility: Demonstrate clean energy commitment to stakeholders

Proven Performance in the Field

A bright blue GEM low-speed electric vehicle with PowerFilm solar panels installed on the roof is parked near a modern white surrounded by palm trees on a sunny day.

Since launch, commercial customers have experienced:

Consistent solar performance in varied climates, including heat and humidity
Fewer plug-in sessions and reduced strain on charging infrastructure
Easier fleet management thanks to "set it and forget it" passive charging

Want to see how similar solar upgrades perform in other LSEVs? Check out our PowerDrive solution for golf cars and other LSEVs.

What's Next for GEM and PowerFilm Solar Integration

With strong initial success, we are continuing to expand this solar solution and plan to:

Retrofit kits for legacy GEM vehicles
Ensure compatibility with new battery technologies and vehicle models

Explore Solar for Your Electric Fleet

Whether you manage five LSEVs or fifty, solar charging is a smart, scalable upgrade. PowerFilm can help you reduce costs, extend range, and enhance your fleet’s sustainability with solar energy solutions for electric fleets.

Learn more and configure your GEM solar kit at: gemcar.com/solar

Interested in a custom solar solution? Contact us today

At PowerFilm, we don’t just make solar. We make solar work for you.