Student ProjectsCustom Flexible Solar Panel Manufacturing
Project Manager
Bill Chen
NUsolar
Amount Requested
$5,000
Summary
This project will enable Northwestern University Solar Car (NUsolar) students to design and manufacture high-efficiency, flexible solar panels tailored to the unique shape of our solar vehicle. Rather than relying on commercially available panels, our team members will develop a repeatable manufacturing process that allows solar cells to be integrated into custom aerodynamic surfaces, maximizing both solar energy generation and vehicle performance. Through this work, they will gain hands-on experience in solar cell integration, composite manufacturing, electrical system design, testing, and process optimization. At the end of the project, we will have a documented production methodology and a set of custom panels ready for vehicle integration. Beyond improving the performance of our current vehicle, this effort will create a foundation for future student-led research and innovation in solar panel manufacturing, ensuring that knowledge and technical expertise are passed on to future generations of NUsolar members.
Planned Activities/Investments
To achieve our project objectives, NUsolar will undertake two primary activities. First, our team members will develop the knowledge and skills necessary to manufacture flexible solar panels through a series of small-scale test panels. These prototype panels will allow students to learn industry-standard lamination and encapsulation techniques while gaining hands-on experience with the production equipment and materials required for panel fabrication. Students will also establish a quality control and testing process, including electroluminescence imaging, current-voltage (IV) curve testing under reference lighting conditions, and temperature performance characterization. This iterative testing phase will provide valuable insight into how manufacturing choices affect panel efficiency, durability, and reliability.
Building on the knowledge gained from these initial prototypes, we will then design and manufacture a complete set of custom solar panels tailored specifically to the geometry of our solar vehicle. Unlike commercially available rectangular panels, these custom panels will conform to the contours of the aeroshell, allowing us to utilize surface area that would otherwise remain unused. The final deliverable will be a fully student-designed and student-manufactured solar array integrated onto the vehicle, along with documented manufacturing and testing procedures that can be used by future NUsolar members and researchers.
Impact
This project will primarily impact undergraduate students on NUsolar's Electrical and Mechanical Engineering subteams by providing hands-on experience in solar panel manufacturing, testing, troubleshooting, and optimization. Through direct involvement in the project, students will develop technical skills in renewable energy systems, advanced manufacturing, and engineering validation while gaining practical experience that complements their classroom education and prepares them for industry careers.
We will evaluate the project's impact through both educational and technical outcomes. Student learning will be measured using pre- and post-project assessments (created by the Electrical team leads) of participants' knowledge and confidence in solar panel manufacturing and testing. Project success will also be measured by the successful fabrication and validation of custom solar panels and the creation of documented processes that can be used by future NUsolar members.
Deliverables
A documented, repeatable manufacturing and testing process for producing custom flexible solar panels, including quality control and validation procedures
A complete set of custom-manufactured solar panels designed for the geometry of our vehicle
The successful integration and deployment of the new solar array on the current NUsolar vehicle
Sustainability
The benefits of this project will extend well beyond the duration of Murphy funding. By developing an in-house solar panel manufacturing process and documenting the associated procedures, knowledge gained through this project will be passed on to future generations of NUsolar students. This will enable future teams to design, manufacture, and improve custom solar panels for subsequent vehicles without having to restart the learning process from scratch. The equipment, materials, and testing capabilities established through this grant are expected to remain in use for many years, supporting both vehicle development and student learning. As future students build on this foundation, we anticipate continued improvements in panel performance, manufacturing efficiency, and research opportunities, allowing the impact of the project to grow over time.
Previous Projects
Murphy funding has continued to support several key components of our vehicle development process. Over the past year, we have worked closely with race officials to gain approval for our braking system, learning valuable lessons about brake system design, factors of safety, brake force transfer, and how to optimize performance while maintaining safety. Funding has also supported the design and manufacturing of our brake rotors. While we successfully produced a full set of rotors, the process revealed challenges such as warping during manufacturing, allowing us to refine our methods and improve future production runs. In addition, we have completed the design of our custom tires and rims, including fully custom wheel rims developed by the team. We are currently finishing the final rounds of finite element analysis (FEA) and coordinating with manufacturers to place production orders. Remaining Murphy funds will be used in the coming weeks to complete manufacturing and procurement activities as these components move into their final stages before vehicle assembly and testing.
Budget Overview
Total Budget Amount: $5,000
Faculty Adviser/Department
Nivedita Arora/Electrical and Computer Engineering