Are today’s solar modules built to last? – with Chiara Baretta and Steven Xuereb

Recorded live in Barcelona at the Solar Quality Summit in
February, this episode of The smarter E Podcast examines a
critical question for the PV industry: are today’s solar modules
built for long-term durability?


As manufacturers push for higher efficiencies, larger formats,
and lower costs, quality data is flashing warning signs. Drawing
on insights from Kiwa PI Berlin’s latest Module Manufacturing
Report, we explore a record 3.36% defect rate observed during
pre-shipment inspections in 2025, and what’s driving it.


Rear-side breakage in large-format, glass-glass modules is
emerging as a major concern, with thinner 2 mm strengthened glass
proving more fragile under real-world stress. At the same time,
thinner frames, rapid factory ramp-ups, and geopolitical supply
chain shifts are adding new layers of risk.


The episode also dives into degradation challenges linked to
TOPCon technology, including UV-induced degradation – and module
meta-stability, which is proving challenging for accurate
characterization.


In the second part of the episode, we turn to polymers – present
in the encapsulants, backsheets, and adhesives that quietly
influence whether modules last 30 years or fail early. New
materials like POE and TPO are improving performance in some
areas, but increasing complexity across the bill of materials.
Meanwhile, emerging tools such as near-infrared field analysis
and AI-supported inspection may help be a helpful root-cause
analysis tool and enabler of predictive maintenance.


If solar is scaling at unprecedented speed, quality assurance
must keep up. Covering a wide range of the important quality
topics at hand, our live conversation Barcelona puts the
spotlight on what it will take to ensure today’s modules truly
stand the test of time.


️ Have comments or questions? Get in touch at
podcast@thesmartere.com