SunCast 861: 1 in 5 Solar Panels Are Failing — Here’s Why
Oct 4, 2025
A shocking 1 in 5 solar panels are failing due to unforeseen issues with glass breakage. Industry experts reveal that tempered glass often isn't up to par, and design shortcuts lead to increased risk. Thin glass might seem cost-effective but can result in costly failures. Discover how contamination and poor silicone placement exacerbate these problems, and learn about essential quality control improvements. This discussion is a must-listen for anyone involved in solar project development!
AI Snips
Chapters
Transcript
Episode notes
Significant Failure Rates In Testing
- PVEL found about 20% of tested module bills of material failed mechanical load tests due to glass breakage.
- Their outdoor lab also saw six of 20 modules break after short outdoor exposure.
Tempered Glass Isn't One Standard
- Thin glass can still be tempered, but the term “tempered” covers different processes with varying durability.
- Some tempering methods used for thinner glass are inadequate for long-term module reliability.
Outdoor Lab Modules Cracked Quickly
- In PVEL's outdoor lab, they placed modules outside just to stabilize them and six of 20 broke within weeks.
- That surprised Tristan and highlights real-world fragility beyond controlled tests.