Reducing costs, enhancing efficiency, and accelerating deployment are critical for the solar industry to effectively compete with fossil fuel-based power sources. Our joint efforts to streamline project costs remain a key factor behind solar energy’s significant contribution, representing 50% of all new electricity-generating capacity added in the U.S. last year.

Presently, one of the most encouraging avenues for ongoing cost reductions, both in module and system domains, revolves around the advancement and implementation of large-format PV modules. The potential benefits are so persuasive that certain industry experts anticipate large-format modules to encompass 90% of the utility market by 2025. Notably, the adoption of large-format products has begun to extend beyond the utility sector and into distributed generation (DG) markets.

Within this piece, I delve into the factors propelling the industry’s shift towards large-format PV modules. I also delve into the distinctive technical risks associated with these novel products and propose strategic methods for risk mitigation. By imparting these perspectives, my aim is not to endorse or criticize any particular product, technology, or manufacturer. Instead, it is to equip you with the knowledge to discern and outline the most suitable products and system configurations for your specific needs.

The advantages of large-format solar modules at a macro level are readily apparent. Utilizing larger wafers and cells, usually sized at 182 mm (M10) or 210 mm (M12) square, enables the creation of larger form factor modules. These innovative modules typically exceed 2 meters in length and boast power ratings spanning from 500 W to over 800 W.

In an industry that has historically seen gradual advancements in module capacity, the introduction of super-sized PV modules signifies a substantial leap in module-level power output ratings. Traditionally, yearly enhancements in cell efficiency lead to output power increases of 10 W to 15 W. In contrast, transitioning from a conventional M6 (166 mm square) wafer format to M10 or M12 wafers could elevate module-level output power by 100 W to 150 W, showcasing a significant boost in performance.