Project Overview
A U.S.-based robotics company approached Sola-E with a highly specialized requirement: develop a custom 7.8W solar panel for a robotic pool cleaner that could float on water, maintain IP67 waterproof protection, and meet a strict total weight target of 155g ±5g.
Unlike conventional solar panel projects, the primary challenge was not power output or waterproofing performance. The client’s product design allowed almost no margin for weight variation. Even small deviations would negatively affect buoyancy, balance, and overall device performance.
After four development iterations and extensive process optimization, Sola-E successfully established a repeatable manufacturing solution that consistently met all requirements and supported stable production over multiple years.
Project Specifications
| Item | Specification |
| Client Location | United States |
| Industry | Robotics & Smart Cleaning Equipment |
| Product Application | Robotic Pool Cleaner |
| Solar Power Output | 7.8W |
| Waterproof Rating | IP67 |
| Weight Requirement | 155g ±5g |
| Development Iterations | 4 |
| Project Duration | 2021–2025 |
| Project Type | Custom ODM Solar Panel Development |
The Challenge
The client required a solar panel that could simultaneously achieve:
- 7.8W power generation
- IP67 waterproof protection
- Floating capability
- Ultra-lightweight construction
- Long-term outdoor durability
- Stable mass production consistency
While many solar panel manufacturers can achieve waterproofing, maintaining precise weight control without compromising structural integrity is considerably more difficult.
The total weight target of 155g ±5g left almost no tolerance for manufacturing variation.
Initial prototypes exceeded the weight limit, making them unsuitable for the client’s application.
Development Process
Iteration 1 – Initial Prototype
The first prototype successfully met electrical and waterproof requirements but exceeded the target weight.
The client rejected the sample due to excessive weight.
Iteration 2 – Material Optimizatio
Our engineering team replaced several lamination materials with lighter alternatives and optimized component selection.
Although weight was reduced, the panel still exceeded the allowable tolerance.
The second sample was also rejected.
Iteration 3 – Process Investigatio
Rather than terminating the project, Sola-E continued development at our own expense.
During this phase, our engineers conducted detailed analysis of the lamination process and discovered that thermal pressing parameters had a significant impact on final panel weight.
Even small changes in temperature and pressing duration created measurable differences in material density and bonding characteristics.
Iteration 4 – Process Optimization
After extensive testing, the engineering team identified the optimal lamination window.
A repeatable process was established through:
- Thermal pressing optimization
- Material density control
- Lamination consistency verification
- Weight monitoring procedures
The fourth prototype successfully met all project requirements and was approved by the client.
Engineering Breakthrough
The key challenge was not waterproofing.
The breakthrough came from understanding the relationship between lamination process parameters and final product weight.
Our team discovered that thermal pressing temperature and cycle time had a non-linear effect on both:
- Panel weight
- Structural integrity
If the temperature was too low, bonding strength became insufficient.
If the temperature was too high, material density increased and weight exceeded specifications.
By identifying the optimal processing window, we created a formal Standard Operating Procedure (SOP) that controlled every critical production parameter.
This process knowledge enabled consistent manufacturing performance across all future production runs.
Production Results
| Metric | Result |
| Target Weight | 155g ±5g |
| Waterproof Performance | IP67 |
| Power Output | 7.8W |
| Development Iterations | 4 |
| SOP Established | Yes |
| Production Consistency | Achieved |
| Long-Term Supply | 2021–2025 |
| Client Approval | Successful |
Applications Beyond Robotics
Although this project was developed for a robotic pool cleaner, the engineering principles are directly applicable to many other weight-sensitive solar applications.
Relevant industries include:
Marine Equipment
Weight reduction and waterproof reliability are critical for marine solar installations and floating systems.
RV & Vehicle Roof Systems
Lightweight solar panels help reduce roof loading while maintaining energy generation performance.
Portable Solar Products
Portable solar chargers and foldable solar panels benefit from lower weight and improved portability.
IoT & Autonomous Devices
Smart sensors, robotics, and autonomous equipment often require compact solar power solutions with strict weight limitations.
Outdoor Consumer Electronics
Waterproof and lightweight solar modules are increasingly used in outdoor electronics and smart products.
Why This Matters for OEM Buyers
Many suppliers can provide standard solar panels.
Far fewer manufacturers can solve engineering challenges involving strict weight tolerances, waterproof performance, and production consistency simultaneously.
This project demonstrates Sola-E’s capabilities in:
- Custom solar panel development
- OEM & ODM manufacturing
- Lightweight solar panel engineering
- IP67 waterproof solar panel production
- Lamination process optimization
- Long-term production control
The final solution required four development iterations, extensive process validation, and a documented manufacturing SOP before achieving production readiness.
For OEM customers developing innovative products, engineering expertise often matters more than standard catalog products.
About Sola-E
Sola-E is a manufacturer of portable and flexible solar panels specializing in OEM and ODM projects for outdoor, marine, RV, robotics, and industrial applications.
Our engineering team supports customers from concept development through prototype validation and mass production.
With expertise in lightweight solar panel design, waterproof solar technology, HPBC solar cells, and custom manufacturing solutions, we help brands bring specialized solar-powered products to market faster and more reliably.
Need a Custom Solar Panel Solution?
Lightweight, waterproof, custom-spec solar panels for your device. We offer end-to-end OEM & ODM engineering support, from prototype design to bulk manufacturing.
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Sam | Solar Application Specialist
With over 10 years of experience in the photovoltaic manufacturing industry, Sam specializes in risk control and application engineering for portable battery chargers and marine solar panel solutions. He helps OEMs and distributors bridge the gap between technical specs and real-world performance.
