Development of New Products for Specific Applications

Module lamination
© Fraunhofer CSP
Module lamination

Apart from cost-saving generation of electricity, specialized modules fulfill further application-specific tasks. At the Fraunhofer CSP we develop new processes and products for these specific applications.

Architecturally demanding solutions and the integration of solar cells into structures like car tops or roofings, require the adjustment of the photovoltaic elements to the respective structure in particular. Among them are, above all, the lamination of brittle solar cells on convex or curved substrates. In our current work we are concerned with the development of adjusted manufacturing procedures in order to embed brittle, crystalline solar cells on top of convex structures. The evaluation of module quality then proceeds by means of electroluminescence and power measurement, revealing that especially the type of the solar cells used has a decisive influence on the lamination quality.

A special focus is set on lightweight construction modules. Here, we optimize the lightweight of the modules, i.e. the value which reports what power can be achieved relative to the weight of the module [W/kg].


  • Manufacture of specialized modules – light, convex, colored
  • Building-integrated photovoltaics (BIPV)
  • Vehicle-integrated photovoltaics (VIPV)
  • Manufacture of modules with small solar cells, e.g. calibration modules


lightweight bike port
© Fraunhofer CSP
Bike port in lightweight construction.

Bike port in lightweight construction

We designed a bike port in lightweight construction in order to combine the operational fields »lightweight construction« and »photovoltaics«. The prototype shows how an appealing design and a concomitant utilization of solar energy can be realized by highly efficient crystalline solar cells, apart from protecting parked bicycles against rain and sunshine.

Roof-integrated solar module system
© Fraunhofer CSP
Roof-integrated solar module system GiSMo.

Building-integrated SolarModule GiSMo

Our roof-integrated solar module system developed for the mass market combines the function of a roof coverage with photovoltaics in one product. The innovative shingle system, which relies on the overlap of the singe lightweight solar module carriers, compensates for seasonal roof expansions. The channels built into the overlapping areas enable the runoff of penetrating water as is usually the case with standard roof tiles, but not with other in-roof solar systems. The concept has advantages also when it comes to its rapid installation and exchanging the solar modules. In the overall costs for a roof-top solar system the actual solar modules make up approximately 22-25 percent of the price, while the remaining costs are incurred by additional elements and the often sophisticated installation. The weight of less than 9 kg/m2 per lightweight construction module accounts for an easy handling on the roof.

biegsam Integration Bau Design
© A. Heller, ai:L der HTWK Leipzig
A façade with facet optics enables a distinctly higher electricity yield. Small and flexible solar modules are perfect to serve this purpose.

In the C3 (carbon concrete composite) project more than 150 partners from science, industry, organizations and associations are committed to promote the application of carbon cement. Instead of mantling steel with concrete, as has been done in previous constructions, carbon-fiber constructs are now supposed to be mantled with concrete.

C3 is considered to be a moldable, stable, intelligent, low-pollution, better recyclable building material and fit for the integration of renewable energies. We at the Fraunhofer CSP are one of the project partners and concerned with the question of how photovoltaic elements can be integrated into cement and electrically wired so that an optimal electricity yield will be achieved.

Of three possible methods to achieve building integration we focus our attention on casting the solar modules directly into their corresponding recesses in the cement parts, laminating or gluing them onto concrete slabs, and finally the attachment of the solar modules by means of snap buttons and screws. The latter method would make the modules removable.

It showed that the electricity yield increases when the facades are not plane. The surface that can be exploited by photovoltaics is increased either by inclination, tilting, domes or facet optics.