Are today’s solar modules built to last? – with Chiara Baretta and Steven Xuereb
About this episode
This episode discusses the durability of modern solar modules and the challenges faced in the PV industry regarding manufacturing defects and material performance.
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…
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