Technology
Using innovative technologies and manufacturing processes, Calisolar has taken a comprehensive, integrated approach to producing silicon and converting silicon into solar cells.
These processes, related to silicon purification, crystallization, wafering, and cell processing, enable Calisolar to mass produce high-performance cells with efficiencies well above 16 percent. This efficiency is achieved using silicon feedstocks that cost a fraction of the conventional, capital and energy intensive Siemens process silicon.
The modules made from Calisolar cells are indistinguishable from other high-performance PV modules designed for grid-tied applications using conventional multicrystalline technologies. Modules manufactured using Calisolar cells have obtained IEC 61730 and IEC 61215 certification from TÜV Rheinland and UL 1703 certification from Underwriter Laboratories.
Vertically Integrated Manufacturing
Calisolar is the only cell supplier with the know-how and capability for a complete, vertically integrated manufacturing process, from initial silicon purification through final cell processing.
Purification
While the Siemens silicon process requires vaporizing silicon, Calisolar purifies silicon in a liquid state at temperatures far below the melting temperature of silicon, consuming a fraction of the energy and achieving 99.9999 percent purity.
Crystallization
The purified silicon is carefully cast in controlled conditions to produce high quality ingots.
Wafering
Ingots are cut into bricks, which are then sliced into thin wafers using abrasive slurry and spools of wire longer than the distance between San Francisco and Los Angeles.
Cell Processing
The wafers are processed through a series of steps in a clean room to form the cells. The optical properties are optimized to capture light, the photovoltaic junction is created, and the cell is metalized to make electrical connections.
The Finished Product
Completed solar cells are shipped worldwide. Customers assemble multiple cells into solar modules, which convert sunlight directly into electricity for grid-tied solar power installations.