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Can you trim or cut a flexible (thin-film) solar panel?

A flexible solar panel is also known as a thin-film solar panel. They are flexible and much thinner than standard crystalline or polycrystalline solar panel that is rigid.

Therefore, they are used in a variety of applications where a standard solar panel would be too bulky. They can be rolled out like carpet or placed on curved surfaces.

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However, there is a question that is often asked, can you cut or trim a flexible solar panel?

Here is what you should know.

A thin-film solar panel has a light-absorbing layer that is one micron thick. Cutting or trimming the panel can partially or completely damage its silicon layer and impair its function depending on where it is cut. Therefore, it’s not a good idea unless absolutely necessary.

In most cases, standard sizes of thin-film panels should be sufficient for your needs. However, if standard sizes are not suitable for your projects, you should instead look for manufacturers that sell custom cut sizes.

There are solar panel manufacturers that offer completely customized solutions according to your specific needs. However, this may or may not be a feasible option depending on your budget or the scale of your project.

But if you still wonder how you could cut your thin-film solar panel without damaging its cells, here is how you can achieve it.

How to cut or trim or cut a thin-film solar panel?

Now we know that thin-film solar panels are flexible and can be cut to size, but how do we get there?

There are two common methods that you can use:

Cutting with scissors or carpet knife

The first method involves using a pair of scissors or a cutting tool like a carpet knife that can cut through a thin sheet of material. While this might sound like something that will be easy, it isn’t because these thin panels are very sensitive and can break easily.

If you choose this option, make sure that your cutting tool is very sharp to cut at a single line.

Things you need:

  • Scissors or a carpet knife,
  • Ruler
  • Pencil
  • Protective gloves
  • Goggles
  • Silicone spray or adhesive tape

What to do:

The first thing you need is a pair of scissors, silicone spray, and protective gloves. Put on the gloves and protect your eyes with goggles. The next step is to use the ruler to measure the length of the panel that you want to cut.

Now make a mark on the panel and then cut it with the scissor or carpet knife along that line. Using scissors would be the easier way to cut it. When you are using a carpet knife, make sure that you are not pressing too hard on the panel or it will break easily.

You can use silicone spray on the edges so it does not get damaged.

If using a carpet knife, be very careful because this tool has a sharp blade that can easily change cutting direction and cut your hand.

Once you are done cutting the panel to your desired size, put it in its place and attach it securely to the surface where you plan to put it.

You also want to cut slowly, applying firm but gentle pressure on the tool so as not to press too hard and crack your solar cells.

Measure the length of your thin-film solar panel and mark with a pen on the outside of the material. Extend a ruler from one line to another so that it forms a straight line across your solar panel. Do this all the way along the length of the material until you have measured it all off.

Cut along these lines so that you are left with a single, long strip of flexible thin-film solar material. you can then cut off some or all of this material to form your new solar cell panels

Cutting with laser

A laser cutter is a better option to use if you have access to one. This is because it will result in cleaner, more accurate cuts than if you were to cut with scissors or a carpet knife.

What you need:

  • A laser cutter
  • Flexible thin-film solar material
  • Ruler

What to do:

Mark your material with a pen and ruler to show. This will be your baseline for cutting.

To use a laser cutter, place the thin-film solar material on your cutting mat using double-sided sticky tape. Place this against the bed of your laser cutter so that it can’t move, and set the laser cutter so that it cuts through the thin-film solar material.

Before pressing the ‘Start button’ on your laser cutter, make sure that the settings are correct. If they aren’t, you may end up with a sticky mess of melted plastic and wasted solar cells!

Once you are sure that your solar cells are in the right place, click ‘Start’. Your laser cutter will begin to emit a thin beam of light. This will be focused downwards onto the thin-film material.

Your laser cutter will be guiding the beam of light, so all you need to do is sit back and relax. Once the laser has completely cut through the thin-film solar cell, remove it from the laser cutter carefully. Now you can check if you have successfully cut the solar cells, by testing the resistance of your new solar cell.

Conclusion:

Although it is possible to cut flexible solar panels, it is not recommended. The thin-film material that the cells are made from is very sensitive and you could easily end up with a thin film that does not work.

Therefore, it is best to look for custom-cut thin-film panels that are at the size or close to the size of the thin-film design for your project. Different manufacturers come up with products with different designs all the time.

That said if you have to trim a flexible solar panel yourself, make sure to cut precisely and to check the integrity of the cells you had cut using a resistance meter.