CubicWatt designs and manufactures custom, high-quality solar panels and mounting solutions for a wide range of industrial applications, including transportation, agriculture, parking and environmental monitoring. We work together to understand your dimensional and power needs, convert them into technical drawings, test for performance within your design and manage the supply chain and import process.

Development process

Our team typically follows a four-step development process:

1. Exploratory Discussion - Phone and/or email conversations to understand your full project requirements, quantities and timeline.

2. Panel Specifications and Design - We prepare one or more panel drawings that include dimensions, materials, voltage, power, wiring and mounting mechanism.

3. Samples - If necessary, we produce samples for testing within your design. There are several mechanisms to test for performance and durability against your specifications.

4. Full Production - Panels are produced at scale. We manage QA and the import process.

Power & Voltage Options

The total power is determined by the surface area and efficiency of the solar cell. We often use both standard monocrystalline cells and SunPower back contact cells.

Custom solar panel

We cut these cells into smaller, even pieces with a laser and mount them in a panel. The more cell surface area, the more power is produced.

Custom Solar Panel Cell Pieces

We gain efficiency by moving tracer lines and connection points to the back of the cells. Although more expensive per watt, compared to traditional monocrystalline cells, these cells have:

• Higher efficiency - approximately 15% additional power per unit area
• Strong copper connections retain power even when a cell is cracked
• Fewer cell size and layout restrictions when using an SMT manufacturing process
• Plain appearance can disappear on a matte black background
• Slightly more physical flexibility

Custom Solar Panel Voltage Where possible we recommend producing the lowest possible voltage panel that will work for your circuit. Here are some benefits of a lower voltage panel:

• Higher current - On the same surface area, an 18V panel will produce less current than a 16V panel. Your circuit can waste that excess voltage, leaving you with 12.5% ​​less power.
• Higher power - Each cell requires a gap between the next cell. The more cells on a panel, the more surface area is wasted on the gaps between the cells.
• Greater risk of partial shading and fouling - If an object sticks to the panel or partially shades the panel, power loss will be greater on a higher voltage panel. An array of cells generates as much power as the worst performer in the array. When cell pieces are smaller, the impact of shading increases.
• Slightly more expensive to produce - more pieces means more labor

Coating Options
We recommend a coating for the panel based on your durability, cost and design requirements. The four options are: Urethane: Very UV resistant and durable. Our urethane solar panels last up to 10 years in the sun with minimal power degradation. The urethane coating is poured or "poured" onto the solar cells and substrate. This removes the air between the cells and creates a solid, protective barrier. It is possible to make the urethane slightly flexible or completely stiff, depending on the thickness and type of urethane. This option has a glossy, slightly amber appearance.

ETFE:

A thin, very UV-resistant plastic that protects the solar cells against the elements. This option is ideal for light, flexible and thin panels. ETFE has a light texture and a glossy appearance. It is possible to add an anti-reflective or anti-reflective layer to the ETFE.

Silicone :

This option is often used for solar panels used in the automotive industry. It is durable and UV-resistant, but has a matte and rubbery appearance. Silicone is ideal for applications where a soft touch and flexibility are required.

Glass: The most durable of all options. Glass solar panels can last for decades without significant power loss. However, they are heavy and can break if bent or hit.

The substrate is what supports the solar cells and gives them their shape. We have three substrate options:

Aluminum: A rigid and durable substrate used for most of our fixed solar panels. It is lightweight, corrosion resistant and can be used with all four coating options.

Polyester: A thin and flexible substrate that is ideal for light and flexible solar panels. Polyester is often used with the ETFE coating.

FR4: A very durable and rigid substrate used for solar panels that have to operate in extreme conditions. It is highly heat resistant and can be used with all four coating options.

Cell Connection vs SMT

The traditional method for connecting solar cells is to solder cell pieces in series or parallel with tabbing wire. This is commonly used for our urethane coated solar panels and is a cost effective way to connect cells.

With Surface Mount Technology (SMT), the cell pieces are soldered to the substrate instead of using tabbing wire. This is often used for our ETFE and silicone coated solar panels and is ideal for producing light, thin and flexible panels.

MC4 connectors: These connectors are ideal for connecting solar panels to a controller or inverter. They are waterproof and ensure a safe and reliable connection.

JST Connectors: These small connectors are ideal for applications where space is an issue. They are lightweight and easy to connect.

Mounting Options We offer various mounting options for our solar panels:

Screw mounting: This is the most traditional method and is ideal for permanent installations. The solar panels are screwed directly to the surface.

Self-adhesive mounting: For temporary or light-duty installations, we offer a self-adhesive backing that can easily be stuck to any surface.

Rail mounting: For larger installations we offer a rail mounting system. The solar panels are screwed onto the rails and then mounted on the surface.

Clamp mounting: This option is ideal for temporary installations. The solar panels are attached to the surface with clamps.

Design & Tooling Costs

When designing a custom solar panel, there are some costs associated with the design and tools required to produce the panel. These costs vary depending on the complexity of the design and materials used. However, we always provide a detailed quote before we start production, so you know exactly what the costs will be.

Minimum Order Quantities

Most of our solar panels have a minimum order quantity of 100 pieces. However, for some special designs or materials this number may be higher. We will always clearly communicate what the minimum order quantity is before we start production.

Supply Chain & Tariffs

We have established an extensive supply chain to ensure we always have access to the best materials at the most competitive prices. We work with some of the best suppliers in the industry and are always looking for ways to reduce costs without sacrificing quality.

We also offer competitive rates for our solar panels. We pride ourselves on providing quality products at great prices