5 Critical Metal Forming Processes in Solar Panel Manufacturing

The solar industry continues to expand at a remarkable pace, driven by falling costs, higher efficiency, and rising global demand for clean energy. While most discussions focus on photovoltaic cell innovation, the metal components that support, protect, and orient those cells are just as essential to long-term system performance.

Every solar installation depends on a network of precisely formed metal parts. From the frames that protect fragile cells to the mounting rails that withstand decades of weather exposure, metal forming processes determine durability, alignment, safety, and even installation labor costs. The quality of these components directly influences whether a solar array performs reliably for 25 years or more.

For manufacturers, EPC firms, and project developers, understanding these forming techniques helps optimize component design, reduce production waste, and improve overall system reliability. In this article, we'll break down five key metal forming processes that underpin modern solar panel manufacturing and installation.

1. Roll Forming for Solar Panel Frames and Mounting Rails

Roll forming shapes long metal strips by guiding them through a series of precisely aligned rollers. Each roller set bends the material slightly until the final profile emerges. This continuous process is ideal for the long, consistent shapes required in solar construction.

The most familiar example is the aluminum frame surrounding each solar panel. These frames must maintain tight dimensional control because minor deviations can disrupt panel alignment, create gaps in large arrays, or complicate installation. Roll forming excels here: it produces uniform profiles with tolerances often held within ±0.5 mm across dozens or hundreds of meters.

Mounting rails for ground-mount and rooftop systems also rely on roll forming. These rails carry significant structural loads, so their profiles often include multiple bends, ribs, channels, and stiffeners (features that roll forming can create efficiently at high speeds).

Material efficiency is another advantage. Since roll forming uses coil stock and forms material directly into shape, it produces minimal scrap compared to cutting rail segments from sheet metal. Across megawatt-scale projects, these material savings add up quickly.

Roll forming also allows manufacturers to integrate features directly into the profile: drainage paths, wire-management channels, clip slots, and fastening interfaces can all be created during forming rather than added later. This reduces installation time and minimizes secondary processes.

Thermal expansion is another design consideration for solar frames. Aluminum experiences seasonal temperature swings of 60°C or more in many environments. Roll-formed profiles can incorporate expansion relief features that help prevent distortion or cracking over time.

The process is most economical for long production runs where the same cross-section is manufactured continuously. Once the tooling is set, changeovers are minimal (an ideal fit for standardized panel sizes and utility-scale manufacturing).

2. Precision Bending for Mounting Brackets and Hardware

While roll forming generates long structural shapes, precision metal bending services produce the countless brackets, connectors, and hardware components that tie a solar system together. These parts ensure panels sit at the correct angle, securely attach rails to roofs or ground structures, and provide pathways for wiring.

Manufacturers begin with flat blanks (usually aluminum, steel, stainless steel, or galvanized steel) cut to size before bending them on press brakes. The bending equipment applies controlled force along precise lines, shaping each piece into its required geometry. For solar applications, bend angles often require accuracy within ±1 degree to ensure proper alignment.

Common examples include L-brackets, Z-brackets, splice plates, mid-clamps, and end-clamps. A single rooftop installation may use dozens of bracket types, each engineered for specific roof styles, mounting surfaces, or environmental conditions.

Material selection depends on the installation environment. Stainless steel resists corrosion in coastal regions; aluminum minimizes weight for roof-limited buildings; galvanized steel provides a cost-effective option for utility-scale ground mounts.

Bend radius plays a significant role in part durability. Tighter bends increase stress and risk cracking, especially in thicker materials. Designers typically specify bend radii between 1.5–3× the material thickness to balance manufacturability with structural integrity.

High-volume components benefit from automated bending cells that load blanks, perform multiple bends, and unload finished parts with minimal labor. For specialized or lower-volume brackets (such as those used in agrivoltaic systems with variable panel heights), manual or semi-automated bending allows cost-effective customization.

Secondary operations (punching holes, adding coatings, grinding edges, attaching hardware) often follow the bending process, ensuring each component is ready for field installation.

3. Stamping for Electrical Connection Components

Metal stamping uses high-force presses and precision dies to cut and shape flat metal sheets at extremely high speeds. Its repeatability makes it ideal for the small electrical components used in large quantities throughout solar systems.

Inside junction boxes mounted on the backs of solar panels, stamped copper or tin-plated copper contacts provide the electrical interface between panels. These contacts must maintain stable conductivity over decades of thermal cycling and environmental exposure.

Stamping allows manufacturers to form spring features directly into the contacts, ensuring consistent pressure against mating connectors. This balance of spring force and ease of installation is critical: too much pressure makes connectors difficult to engage, too little reduces long-term reliability.

Because performance depends on precise geometry, stamping operations rely heavily on automated inspection systems that measure contact features in real time. Even slight variations can increase resistance and create hot spots, compromising both safety and panel lifespan.

Grounding clips are another essential stamped component. These clips create electrical bonds between metal frames and mounting structures, forming part of the system's grounding and lightning-protection strategy. Their teeth and spring sections must grip aluminum reliably despite vibration, thermal cycling, and corrosion.

Stamped clips and brackets also play a significant role in cable management. Properly securing wiring reduces chafing, minimizes strain, and keeps maintenance straightforward. Stamping makes it economical to produce thousands of identical clips with consistent performance characteristics.

Progressive stamping (where material moves through a series of stations performing cutting, forming, and bending steps) enables complex part geometries. By the final station, a fully formed part emerges, ready for assembly.

Stamped components used in solar systems typically range in thickness from 0.5 to 2.0 mm. Designers select thickness based on structural needs, conductivity requirements, and press capacity.

4. Tube Bending for Tracker System Structural Elements

Single-axis and dual-axis solar trackers increase energy production by 15–35% by following the sun throughout the day. Their mechanical frameworks rely on hollow structural tubing, shaped through precision tube bending.

One of the most critical elements is the torque tube (a large-diameter tube, 100–200 mm in diameter, that spans between supports and carries rows of solar panels). These tubes endure torsional loads, wind forces, and panel weight, all while maintaining strict alignment.

Straight torque tubes connect to bent end sections that interface with bearings. These bends typically range from 15° to 45° and must form without wrinkling, flattening, or thinning the tube walls (defects that weaken the structure or reduce fatigue life).

Mandrel bending is often used to achieve clean, uniform bends. An internal mandrel supports the tube's inner wall during bending, preventing collapse and maintaining structural integrity. Parameters like bend radius, mandrel type, lubrication, and feed rate must be precisely controlled.

Tracker drive systems also use bent tubes, including actuator arms and linkages. These smaller tubes bend more easily but still require tight tolerances to ensure smooth mechanical motion.

Using bent hollow tubing provides significant weight savings over solid structures. This is especially important in areas with poor soil conditions, where reducing system weight can eliminate costly foundation upgrades.

Quality inspection includes dimensional checks, non-destructive testing, and periodic destructive testing of sample parts. These tests ensure bends do not compromise tube strength and that geometry remains within design limits for the tracker's 25-year life.

Material selection varies by environment: galvanized steel works for most climates, stainless steel resists coastal corrosion, and aluminum offers weight advantages where structural loading is limited.

5. Extrusion and Subsequent Forming for Custom Profiles

Aluminum extrusion forces heated aluminum through a shaped die to create continuous profiles with highly customized cross-sections. While extrusion is a standalone process, many extruded components require secondary forming steps before reaching their final shape.

Heat-sink extrusions for inverters and power electronics are a prime example. These profiles include complex fins that maximize surface area for cooling. After extrusion, sections may be bent or notched to fit enclosures without compromising thermal performance.

Wire-management channels also rely on extrusion. Designers can include integrated cable pathways, snap-on covers, and mounting features directly in the profile. Secondary drilling, cutting, and bending customize each piece for specific installation needs.

Extrusion provides significant design flexibility. Mounting rails, for example, can include integrated T-slots that remove the need for drilling and allow installers to slide hardware into position. Wire channels can incorporate snap-fit features that eliminate screws or clips.

Some components combine extrusion and bending to create geometries that neither process alone could achieve. For instance, an extruded profile optimized for stiffness may be bent into a specific installation angle, balancing strength with geometric requirements.

Extrusion tolerances typically hold cross-sectional features within ±0.2 mm, but length and straightness must be tightly controlled (especially for profiles intended for bending). Any initial curvature amplifies during forming.

Heat treatment also matters. Many solar components use 6000-series aluminum alloys, which achieve their full strength after aging. However, fully aged alloys are more complex to form, so manufacturers must coordinate extrusion, creating, and post-processing in the correct sequence.

While extrusion dies require upfront investment (usually $5,000–$25,000 depending on complexity), they enable rapid design iteration and cost-effective production at scale once the design is finalized.

Conclusion

Metal-forming processes shape raw aluminum and steel into precisely engineered components that make modern solar energy possible.

Roll forming delivers long, consistent profiles for frames and rails. Precision bending creates the brackets and hardware that hold systems together. Stamping produces high-volume electrical connectors with exacting consistency. Tube bending forms the structural backbone of solar trackers. Extrusion and secondary forming enable the production of complex, feature-rich profiles tailored to specific applications.

As panel prices decline, balance-of-system components are increasingly accounting for a growing share of project costs. Efficient metal forming (optimized materials, low scrap rates, integrated features, and streamlined installation) plays a significant role in driving solar expenses even lower.

Reliability is equally important. Solar installations are expected to perform for 25 years or more, and metal components must match that durability. Properly formed parts maintain alignment, resist corrosion, and withstand constant thermal cycling and environmental stress.

As solar technology evolves (larger modules, bifacial designs, higher power densities, lighter trackers), metal forming suppliers must continue innovating. Manufacturers that invest in advanced forming capabilities can support new product designs, improve quality, and reduce costs across the entire value chain.

The metal-forming processes outlined here will remain foundational to the solar industry's growth, ensuring that solar power systems continue to become stronger, more efficient, and more cost-effective year after year.