Shaping a greener tomorrow, PowerFilm, Inc delivers sustainable custom solar energy solutions
Founded in 1988, PowerFilm, Inc (PowerFilm) began its journey as a research organization in Ames, Iowa. The company was established with the goal of developing new solar materials capable of producing clean energy from the sun using a low-cost roll to roll manufacturing process and was initially supported by the Department of Energy.
The founders soon created a unique composition of fine solar film, designed specifically for flexible substrates using amorphous silicon. Once the material was perfected, the PowerFilm team went on to design and build the specialized manufacturing equipment required to scale production and commercialize the technology.
The company kept its research, development, manufacturing equipment design, and manufacturing activities in-house, building a self-sustaining network of advanced equipment and machinery. As President, Daniel Stieler, reveals: “We have our own people working across every aspect of the business. From production to advancement and innovation, everything is conducted in-house by the PowerFilm family.
“Our amorphous silicon product is manufactured as a large-scale roll, using one-to-two-mil polyimide as the backing for our solar film. A standard roll is 33 centimeters wide and approximately one kilometer long, which means our manufacturing process is designed specifically for high-volume production.”
With solar technology at its core, PowerFilm Solar offers solar power solutions across a range of applications and sectors. As Daniel confirms: “You can find application specific solar modules in both military and commercial applications. For example, we make products for applications ranging from flagpole lights and IoT devices to autonomous sea vehicles and semi-trucks.
Solar Technologies
Today, the company offers an all-encompassing range of products and services including multiple solar technologies (amorphous silicon, crystalline silicon, and gallium arsenide), cabling, and electronics. As Daniel details: “We work with companies of all sizes to match the right solar technology to their specific applications. There is a custom dimension to the work we do. Customers often approach us with their product or process, and we’ll help them integrate our solar technology into it.
“On the other side of the business, we also provide more standard solutions for larger industrial markets. For example, we have been working closely with customers in commercial transportation, providing off the shelf solutions for jump start avoidance, comfort system power, telematics reliability, and battery life extension. We offer solutions that seamlessly integrate into trailers, class 8 trucks, transportation refrigeration units, and lift-gates.
“There is strong demand for solar technology, along with some exciting opportunities for applications across the transport sector. In the past 12 months alone, we have launched a full product line for Class 8 truck charging systems and lift-gates.
“One of our class 8 truck systems is designed to charge auxiliary power units that support vehicle equipment such as air conditioning systems, refrigerators, and microwaves. We provide high performance systems that maintain battery health, which, depending on the application, can extend battery life from two-to-five years.”
In addition to solar solutions, PowerFilm also provides other contract manufacturing services that are complementary to its manufacturing processes. PowerFilm has completed projects in industrial sewing, thin film deposition, reactive ion etching, electronic design and assembly, and cable assembly. One notable project involved the production of thin film transistors for flexible displays.
“Beyond being a sustainable alternative, our technology delivers reliability and peace of mind. We keep our business agile by balancing custom manufacturing, contract services and standardized product lines.”
As a forward-thinking enterprise, PowerFilm Solar invests heavily in research and development. Driven to improve manufacturing processes and increase efficiency, the company continues to push the boundaries of solar technology.
“A lot of the time we partner with different organizations, giving our research and development activities a clear goal to work towards. We have worked alongside the US Department of Defense for some time, and that’s always been a positive experience for both parties.
“This kind of work helps us grow the business, as it provides new strategies for refining our operations – whether through greater efficiency, higher yield, or increased capacity. It also benefits the end customer, as the innovations often reduce costs and shorten lead times.
“We have done a lot of internal automation and built up an exemplary team of experts in all areas. These advancements help us remain competitive with foreign-produced goods without compromising on quality or output,” Daniel affirms.
As PowerFilm Solar nears its 40th anniversary, Daniel considers the driving forces behind its enduring success: “We have always been able and willing to learn. Over the years, the business has adapted its offerings to reach new markets. We have opened our manufacturing process to enable custom solutions and, through it all, continued to invest in new technologies and ideas.”
As PowerFilm Solar continues to shape a sustainable future for industrial partners and end users alike, Daniel and his team now look forward to what lies ahead: “Our mission has always been to become the go-to provider of custom solar solutions across the US and beyond. In the coming years, I’d like to see the business establish a larger presence in the transportation sector, through both off-road solutions for construction equipment and over the road vehicle enhancements.
“Beyond that, we’ll continue to stay closely aligned with the needs of the industry. Solar power lends itself to a wide range of applications, and our focus is on exploring those opportunities to ensure our technology is used to its full potential. There are still plenty of unrealized possibilities in solar, and much more to discover,” he concludes.
Founded in 1988, PowerFilm, Inc (PowerFilm) began its journey as a research organization in Ames, Iowa. The company was established with the goal of developing new solar materials capable of producing clean energy from the sun using a low-cost roll to roll manufacturing process and was initially supported by the Department of Energy.
The founders soon created a unique composition of fine solar film, designed specifically for flexible substrates using amorphous silicon. Once the material was perfected, the PowerFilm team went on to design and build the specialized manufacturing equipment required to scale production and commercialize the technology.
The company kept its research, development, manufacturing equipment design, and manufacturing activities in-house, building a self-sustaining network of advanced equipment and machinery. As President, Daniel Stieler, reveals: “We have our own people working across every aspect of the business. From production to advancement and innovation, everything is conducted in-house by the PowerFilm family.
“Our amorphous silicon product is manufactured as a large-scale roll, using one-to-two-mil polyimide as the backing for our solar film. A standard roll is 33 centimeters wide and approximately one kilometer long, which means our manufacturing process is designed specifically for high-volume production.”
With solar technology at its core, PowerFilm Solar offers solar power solutions across a range of applications and sectors. As Daniel confirms: “You can find application specific solar modules in both military and commercial applications. For example, we make products for applications ranging from flagpole lights and IoT devices to autonomous sea vehicles and semi-trucks.
Today, the company offers an all-encompassing range of products and services including multiple solar technologies (amorphous silicon, crystalline silicon, and gallium arsenide), cabling, and electronics. As Daniel details: “We work with companies of all sizes to match the right solar technology to their specific applications. There is a custom dimension to the work we do. Customers often approach us with their product or process, and we’ll help them integrate our solar technology into it.
“On the other side of the business, we also provide more standard solutions for larger industrial markets. For example, we have been working closely with customers in commercial transportation, providing off the shelf solutions for jump start avoidance, comfort system power, telematics reliability, and battery life extension. We offer solutions that seamlessly integrate into trailers, class 8 trucks, transportation refrigeration units, and lift-gates.
“There is strong demand for solar technology, along with some exciting opportunities for applications across the transport sector. In the past 12 months alone, we have launched a full product line for Class 8 truck charging systems and lift-gates.
“One of our class 8 truck systems is designed to charge auxiliary power units that support vehicle equipment such as air conditioning systems, refrigerators, and microwaves. We provide high performance systems that maintain battery health, which, depending on the application, can extend battery life from two-to-five years.”
In addition to solar solutions, PowerFilm also provides other contract manufacturing services that are complementary to its manufacturing processes. PowerFilm has completed projects in industrial sewing, thin film deposition, reactive ion etching, electronic design and assembly, and cable assembly. One notable project involved the production of thin film transistors for flexible displays.
“Beyond being a sustainable alternative, our technology delivers reliability and peace of mind. We keep our business agile by balancing custom manufacturing, contract services and standardized product lines.”
As a forward-thinking enterprise, PowerFilm Solar invests heavily in research and development. Driven to improve manufacturing processes and increase efficiency, the company continues to push the boundaries of solar technology.
“A lot of the time we partner with different organizations, giving our research and development activities a clear goal to work towards. We have worked alongside the US Department of Defense for some time, and that’s always been a positive experience for both parties.
“This kind of work helps us grow the business, as it provides new strategies for refining our operations – whether through greater efficiency, higher yield, or increased capacity. It also benefits the end customer, as the innovations often reduce costs and shorten lead times.
“We have done a lot of internal automation and built up an exemplary team of experts in all areas. These advancements help us remain competitive with foreign-produced goods without compromising on quality or output,” Daniel affirms.
As PowerFilm Solar nears its 40th anniversary, Daniel considers the driving forces behind its enduring success: “We have always been able and willing to learn. Over the years, the business has adapted its offerings to reach new markets. We have opened our manufacturing process to enable custom solutions and, through it all, continued to invest in new technologies and ideas.”
As PowerFilm Solar continues to shape a sustainable future for industrial partners and end users alike, Daniel and his team now look forward to what lies ahead: “Our mission has always been to become the go-to provider of custom solar solutions across the US and beyond. In the coming years, I’d like to see the business establish a larger presence in the transportation sector, through both off-road solutions for construction equipment and over the road vehicle enhancements.
“Beyond that, we’ll continue to stay closely aligned with the needs of the industry. Solar power lends itself to a wide range of applications, and our focus is on exploring those opportunities to ensure our technology is used to its full potential. There are still plenty of unrealized possibilities in solar, and much more to discover,” he concludes.