Origami Solar Success Story

    "Welser Profile operated with tremendous integrity and truly was interested in solving problems … they have been the ideal partner for us to validate that our designs can be made, give us feedback on how do we make the product more manufacturable and literally accelerating this transition."

    Gregg Patterson
    CEO | Origami Solar

    At a glance

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    CLIENT

    Origami Solar

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    SPECIFICATIONS

    Robust to deal with extreme weather, high corrosion resistance, easy to use and mounting onto existing racking & tracker systems.

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    RESULTS

    A roll formed frame (domestically produced versus imported from China) with a better structural performance than aluminum frame. Optimized emissions balance.

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    DEVELOPMENT

    Development and production of steel frames for solar panels. Transition from aluminum to steel.

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    REQUIREMENTS

    Same form as the current aluminum frames in order to make transition easy, low cost, and minimal risk. Keep current installation methods for customers.

    Challenge

    The PV solar module market is experiencing significant growth, driven by a global push towards more sustainable energy sources. The prevailing standard for solar module frames involves the use of aluminum, despite it being more expensive than steel and lacking the same level of robustness. Furthermore, a notable aspect of the solar industry is its heavy reliance on China, where approximately 90 % of solar modules, including their aluminum frames, are manufactured. In light of recent geopolitical developments, there's a growing urgency to achieve energy independence, prompting a reassessment of the solar module supply chain.
     
    Recognizing the limitations of aluminum and the geopolitical factors influencing the solar industry, Origami Solar designed a more valuable solution, switching from aluminum to steel. Though there are many steel fabricators, it was not easy to find a partner that could deal with the complexity of their product. 
     
    Origami Solar's quest for innovation and independence led them to our experts at Welser Profile, as we are known as a reliable partner for complex development projects. Our willingness to take on the challenge, solving the problem together and ultimately producing an outstanding product became the catalyst for a connection that resulted in a promising relationship.
     

    Solution

    In close connection with Origami Solar, we were able to design and manufacture a complex profile that is easy to use in installation, comparable in cost to the aluminum equivalent, protects the PV Module better, and reduces GHG emissions drastically. 

    From initial discussions questioning the feasibility of a possible steel frame, to joint design improvements to Origami Solar's product, prototyping and the optimization of their now production ready frame, the development was characterized by the shared vision of improving the solar industry. Through the limitations of the Covid-Pandemic, personal meetings were not possible until recently, and most of the developments were made together virtually. 

    It was clear from the beginning that roll forming would be the obvious choice of production as it allows for holes and punch features in an inline continuous string process and additionally is a great fit for a larger scale production.

    efficient

    way of production

    roll forming more efficient than aluminum extrusion as downstream processes can all be integrated into the one roll-forming process.

    3x

    cheaper

    Roll-formed steel profiles are extremely cost-effective and can be manufactured three times more economically than comparable european aluminum frames.

    sustainable

    domestic production

    independent from major producers in Asia enabling the development of a sustainable and emission-reduced product life cycle.

    "The combination of steel and roll forming provides a strategic cost advantage and more value, but it also provides a more scalable solution, in other words, how do you support this size of a market and roll forming seem to be the logical best answer."

     

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    Gregg Patterson
    CEO | Origami Solar

    Impact of the cooperation

    Next to cost savings and improved material qualities, sustainability plays a big factor in the cooperation of Origami Solar and Welser Profile. While aluminum is carbon-intensive, the transition to recycled steel results in a remarkable reduction of carbon emissions.

    In a compelling environmental contrast, for every module produced, the carbon footprint can be curtailed by an impressive 80 kilograms when using recycled-steel frames. This shift not only underscores the commitment to sustainability but also demonstrates the tangible impact that material choices can have on reducing the overall environmental impact. Our partnership therefore, not only underlines the importance of strategic collaborations in the renewable energy sector but also highlights the value of industry leaders joining forces to advance sustainable technologies.

    We at Welser Profile are particularly proud to be the partner of choice in this project as sustainability is part of our own strategy. What does this mean for us in practical terms? While the transition in the steel industry to the use of "green steel" progresses, the environmental impact of the choice of materials will be even greater and the contribution we can make will be enormous. Bring on the future challenges! We are ready! 

    Future outlook

    The transition from aluminum to steel needs to be made for obvious reasons. Together, Origami Solar and Welser Profile validated the superiority of steel module frames. 

    The biggest challenge that lies ahead is the size of the market and its growth over the next few years. The impact, however, is huge and we cannot wait to see where our realtionship with Origami Solar is leading us. 

    About Origami Solar

    Origami Solar has eliminated the solar industry’s reliance on aluminum frames, unlocking dramatic reductions in environmental impact (GHG), cost savings, and opening up the opportunity for domestic production on a global basis.

    Visit their website →

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