Yes, it is possible to make a solar panel in a custom shape. At Voltaic, we manufacture custom and standard small solar panels and while most are rectangular, we have experience designing and deploying a full range of interesting shapes and sizes.
Why Most Solar Panels are Rectangular
Most standard small solar panels are rectangular in shape because they are easier to manufacture and offer the most efficient use of space. Each solar panel is constructed of one or more strings (in series) of individual solar cells. Strung by hand or machine, the strings are in a straight line using equally sized cell pieces. There is very little wasted material or space and the end result is a panel with consistent borders between the cells and the edge of the panel.
Rectangular Solar Panel
How Cutouts and Curves are Made on a Solar Panel
For small panels using PCB / FR4 as the substrate and an ETFE coating, we manufacture the substrate to the desired shape. Then, after the cells, encapsulant (EVA) and coating are applied, we laser cut the assembly again. This process has a lot of flexibility and we have created a large variety of panels with this technique.
SunPower Custom Panel with Curves
Round Solar Panel with SunPower Cells
Laser cut hole in ETFE solar panel
We have less flexibility with our glass and urethane solar panels due to the thickness of the structural element. A water jet or CNC machine is required to cut the urethane substrate or glass. Interior corners are difficult to do and may require special tooling.
Round urethane solar panel
Glass solar panel with inset and through holes
Custom Solar Panel Shapes Use Space Less Efficiently
We are happy to make custom-shaped solar panels, but they will be more expensive per Watt and generate less power per area than rectangular panels. First, the cells on a non-rectangular panel will cover a lower percentage of the available surface area. If you look at this circular panel vs the rectangular panel of similar power levels, the circular panel covers X% less area.
Round Solar Panel Technical Drawing
| Rectangle | Round | |
| Total PCB Area (mm^2) | 8,814 | 18,860 |
| Solar Cell Area | 6,585 | 12,960 |
| % Area Used | 75% | 69% |
Second, the cost increases because we need to throw away more materials in the production process. Again, looking at the circle, we are throwing away all the red sections for PCB, EVA, and ETFE.
Wasted Materials on a Round Solar Panel
Ultimately, the decision to make a custom solar panel in a custom shape depends on a wide variety of factors. If you’re willing to dig into the details, so are we. Do you have a project that requires a custom solar panel? Use the button below to talk to one of our custom solar panel experts.
I’m building a camper van and l think l have room for a panel 5×14 or70 cells. What would be the OD for length and width and estimated cost.
Thanks Doug
Unfortunately, we cannot make custom solar panels at that scale. We focus on high volume production. Good luck with the project.
Can your panels be flexed enough to attach to a car or van roof
We do not make many flexible panels. We have folding panels where the “fold” occurs in between the cells. In general, once the substrate bends, you tend to have shorter lifespans due to increased stress on the lamination as well as pressure on the cells. There are lots of 100 Watt solar panels on the market that advertise themselves as “semi-flexible” and will bend enough to adhere to a car roof. I wouldn’t count on a long lifetime, however.
Are triangular shaped solar panels a possibilty? Many rooves have hips and valleys where a triangle would be a more efficient shape.
Yes – here’s an example (not by us) that takes this approach – https://blog.google/outreach-initiatives/sustainability/dragonscale-solar/
Custom solar panels for roofing is an option, but is non-trivial due to design challenges (higher temps, wiring) and UL certifications. It tends to only make sense at a very large scale vs one-off custom designs.