How Solar Panels Are Made and DIY Solar Panel Guide

the most abundant energy source is the Sun have you ever wondered how solar panels are manufactured and more to it

how you can make one from home today we'll delve into exactly this and at the end of this video you might consider to

make your own power source but first we explore how solar panels are manufactured on an industrial and how

you can create your own at home the Journey Begins with sand specifically quartz sand most solar

panels are made of silicon which is the main component in natural beach sand silicon is abundantly available making

it the second most available element on Earth after oxygen it's out of the Quarry and into the fire the first stage

is to get the Silicon out of the rocks and that's done in this enormous furnace temperatures reach over 2,000 de C this

is unbelievably hot and also quite dangerous silicon is used to make everything from window glass to the

processes in your home computer and without it a solar panel just wouldn't work the purified silicon is melted and

formed into ingots which serve as the raw material for solar Wafers these ingots are produced using either the

sokowski process or the float Zone method in the chowski process a seed crystal is dipped into molten silicon

and slowly withdrawn to create a cylindrical Ingot this block would be far too big to put on your roof which is

where solar panels usually go the average roof wouldn't support it so now it needs to be cut down to size the

Silicon ingots are sliced into thin Wafers using a wire saw a process that requires Precision to minimize material

loss these Wafers typically less than 200 micrometers thick undergo surface treatment to remove any remaining

impurities and defects an anti-reflective coating is applied to the front surface of the wafer to

enhance light absorption allowing for greater efficiency in converting sunlight into electricity and the

subsequent drying process ensure Optimum surface cleaning all Wafers are then measured by fully automated sensors and

cameras and graded according to their thickness and surface quality in The Next Step each wafer is processed into a

solar cell capable of converting sunlight into electricity metal conductors typically made of silver or

aluminum are screen printed onto the wafer to create a grid-like matrix ensuring uniform distribution of

electrical current the wafer is then treated in a high temperature furnace where phosphorus is diffused into the

surface to create a negative electrical charge this combined with the Bor and doped region forms the essential PN

Junction necessary for solar cell operation solar panel after this 6E class in chemistry and physics which we

did in 3 minutes we go to the fun part Assemble the solar cells are interconnected to form a solar panel

with various configurations available depending on the desired output and application the cells are typically

soldered together using conductive adhesives or laser welding creating a series or parallel

connection once interconnected the cells are encapsulated within a protective layer typically made of ethylene vinyl

acetate Eva to ensure durability and weather [Music]

resistance a junction box containing diodes and connectors is attached to facilitate

electrical connections and output I know that was an entire college diploma relax here is the fun part now all completed

modules undergo a rigorous series of tests to ensure their durability and reliability beginning with an infrared

camera screening the initial test meticulously examines the modules for any micro cracks at the cell level

ensuring structural Integrity from the outset following this the modules undergo a flash test to gauge their

performance performance under standard operating conditions next the modules are subjected to a mechanical loading

test simulating harsh environmental conditions such as strong winds heavy snow loads and static pressures like ice

accumulation this test measures the modules resilience and ability to withstand extreme weather scenarios

furthermore modules undergo impact testing to assess their durability against heavy impacts ensuring they can

endure unfor seen incidents without compromising functionality innovatively proprietary tests such as the highly

accelerated stress test are employed to understand how materials and components evolve over time providing invaluable

insights into long-term performance additionally infrared testing is conducted to analyze the module's

temperature during operation under direct sunlight ensuring optimal thermal management finally modules are subjected

to eight distinct testing Chambers to evaluate their behavior under heavy humidity intense UV exposure and various

harsh weather conditions including heat waves and hail storms once testing and quality control are completed packaging

materials are carefully selected to provide adequate protection during transportation and storage solar panels

are typically shipped in pallets or containers with appropriate labeling and documentation to facilitate handling and

installation having the knowledge on commercial panel helps this Nest step of your Pursuit

interesting building a DIY solar panel can be an exciting project and you've with a great outline the steps become

easy let's break down each stage further first designing the layout assessing available space and selecting the

appropriate type of solar panel are crucial initial steps whether you're opting for monoc crystallin or poly

crystallin cells understanding your energy needs and available space help in determining the layout second step is

material cutting and workspace setup precise cutting of materials and setting up a well organized workspace with

proper lighting and ventilation are essential for safety and efficiency adequate air flow facilitates soldering

and encapsulation processes later on there are many ways of acquiring solar cells mostly from platforms like eBay

simplify the process ensure you select cells with a watt rating that that aligns with your energy requirements and

available space the fun begins when it's time for connecting the cells soldering cells

together to form an array requires attention to detail and proper technique techniques like tabbing and

stringing help optimize energy production and minimize shading between cells during and after

installation once all is done encapsulation which is protecting the solar cells from

environmental elements is crucial for longevity and performance a fixing cells to a backing

material and sealing panel edges with waterproofing materials like silicone Shield against moisture Ingress and

enhance durability proper wiring is essential for ensuring the efficient flow of

electricity generated by your solar panel this involves connecting the solar cells in series or parallel

configurations depending on your desired voltage and current output finally testing should be rigorous using

equipment like a multimeter allows you to assess the panel's performance under various conditions this step enables

adjustments to optimize efficiency and reliability the installation and mounting the panel should be secure and

safety should be considered when establishing a WI wiring connection once your DIY solar panel is ready follow the

wiring connections we discussed earlier to connect it to the battery bank and inverter after making the connections

conduct thorough system testing to verify that everything is functioning as expected this includes checking the

charging process inverter operation and overall system performance finally establish a routine for monitoring and

maintaining your solar power system to ensure long-term reliability and efficiency regularly check battery

levels inspect wiring connections and perform any necessary maintenance tasks throughout the process detailed

instructions and careful attention to each step will help you create a functional and reliable solar panel

array experimenting and learning along the way can be part of the fun if you enjoyed this video here is another video

that you can watch on how car body parts are manufactured enjoy