How are solar panels manufactured?
Before we get into how a solar panel is made, let's look at the types of solar panels. They're all typically made from silicon crystals, but they differ in how the crystals form the panels.
» LEARN MORE: Best solar companies
Types of solar panels
Panels are separated into categories depending on the way the silicon is used:
- Monocrystalline solar panels: These use a single silicon crystal for each cell. These are the most efficient type of panels but usually cost more.
- Polycrystalline solar panels: Made from multiple silicon crystals in each cell, these panels are cheaper because they are easier to produce. They are a little less efficient than monocrystalline panels, though.
- Thin-film solar panels: These inexpensive panels are made from layers of silicon. They are lightweight and typically used for smaller solar projects, not whole-home usage.
Additional solar panel subclassifications
Solar panels are divided into two subclassifications due to how they are constructed.
- PERC: PERC solar panels are monocrystalline or polycrystalline panels with a layer of material on the back of the silicon that bounces sunlight back through the panel to make it more efficient.
- Bifacial: Bifacial panels are mounted laterally and have solar cells on both sides. Think of this panel like two back-to-back sandwiches.
Manufacturing process
Solar panels are a lot like a sandwich. You start with the bottom layer, which is a polymer material. Then, cells are added to the panel. The cells are made with a positively charged layer of silicon and a negatively charged layer to create an electric field.
The cells are then joined together with wire to make one big piece on top of the polymer material. A layer of glass tops off the sandwich.
After the panel is done, a junction box and wiring are added to the solar panel. Finally, everything is put into a frame, and the mounting assembly is attached.
End-of-life-recycling
Today's solar panels have an average lifespan of 25 to 35 years, but it's important to consider what happens to them after they're no longer usable. Multiple facilities across the United States recycle silicon and cadmium telluride photovoltaic modules.
Unfortunately, the cost of recycling solar panel parts is still currently higher than the cost of disposing of them in a landfill, but technological innovations will help the U.S. Department of Energy (DOE) Solar Energy Technologies Office (SETO) improve end-of-life recycling.
» LEARN MORE: Types of solar panels
How solar panels work
Solar panels collect radiation from the sun and turn it into energy that your home can use. The cells in the panel absorb the light, and the energy created by the light interacting with the electric fields from the cells is converted from DC to AC using a solar inverter.
From there, it’s pumped into your home’s electric system or stored in a solar battery. You can learn more about the process by checking out our guide on how solar energy is made.
» DISCOVER: How is solar energy stored?
FAQ
How much do solar panels cost?
In 2025, typical solar panels for a residential home cost around $28,241. Federal tax credits bring that cost down to around $19,873.
NOTE: Under the “One Big Beautiful Bill Act” signed in July 2025, the federal solar tax credit is now set to expire at the end of the year, much earlier than previously expected. You must install and pay for your system by Dec. 31, 2025, to receive the 30% tax credit.
» LEARN MORE: How does the federal solar tax credit work?
Where do materials for solar panels come from?
The major material, silicone, is made from sand melted at high heat. Metals that are used to make the panels, such as indium, cadmium, germanium, gallium, tellurium and selenium, are byproducts of the production of other metals.
How long do solar panels last?
Solar panels can last 25 years or more. Even after 25 years, most can still produce 80% of the power they could produce when they were brand new.
Article sources
ConsumerAffairs writers primarily rely on government data, industry experts and original research from other reputable publications to inform their work. Specific sources for this article include:
- U.S. Department of Energy, “Solar Photovoltaic Manufacturing Basics.” Accessed Nov. 18, 2025.
- U. S. Department of Energy, "Homeowner’s Guide to Solar." Accessed Nov. 18, 2025.
- Center for Sustainable Energy, “Solar Energy Adoption: Information for Homeowners and Small Businesses.” Accessed Nov. 18, 2025.
- American Solar Energy Society, “Monocrystalline vs Polycrystalline Solar Panels.” Accessed Nov. 18, 2025.
