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.

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