A Major Leap in Solar Manufacturing: Origami Solar's Groundbreaking Production Line
Origami Solar has announced the commissioning of its first state-of-the-art automated steel solar module frame production line at Priefert Steel’s Benton, Arkansas facility. This marks a significant milestone for the company, highlighting its commitment to meeting the growing demand for steel frames in the U.S. solar industry. With the U.S. government set to impose a 25% tariff on all imported steel and aluminum, the timing of this development couldn’t be more crucial.
This new production line has been developed in close collaboration with Priefert Steel, a leading player in steel roll-forming for the solar industry, and DAC Robotics, an automation expert. Together, they have designed a highly efficient and automated manufacturing process that transforms flat steel coils into complete, high-performance solar module frames at an impressive speed.
Steel Frames: A Superior Alternative to Aluminum
Origami Solar’s steel frames present a powerful alternative to the traditionally used aluminum frames in solar modules. Not only are steel frames significantly stronger, but they also boast a 90% lower carbon footprint compared to aluminum frames. Additionally, steel frames allow for rapid domestic transport, taking just 1-2 days to reach their destination, compared to longer and more uncertain shipping times for imported aluminum frames.
The shift from aluminum to steel is more than just a technical improvement. It addresses several critical challenges facing the U.S. solar manufacturing industry, including the risks associated with relying on overseas supply chains that are vulnerable to geopolitical instability, delays, and tariffs. With rising costs for imported aluminum and steel, the new production line will enable Origami Solar to provide a domestically sourced alternative that is both more cost-effective and more secure.
Leveraging Automation for High-Volume Production
The new automated system implemented at the Benton facility represents the cutting edge of solar frame manufacturing. This high-tech solution integrates continuous steel frame forming with customer-specific frame lengths, hole punching, and corner key insertion, all within seconds. The system, developed by DAC Robotics, also includes an in-line final assembly and packaging process, which ensures that each component meets the highest quality standards while maximizing production efficiency.
Priefert Steel’s expertise in steel production, combined with DAC Robotics’ automation, allows Origami Solar to produce frames at a scale that meets the increasing demand for solar energy systems across the U.S. This automation not only improves the precision of manufacturing but also reduces waste, making the process more sustainable and cost-efficient.
The Strategic Partnership: Strengthening U.S. Manufacturing
The partnership between Origami Solar, Priefert Steel, and DAC Robotics represents more than just a manufacturing solution—it’s a strategic move to strengthen the U.S. solar supply chain. Gregg Patterson, CEO of Origami Solar, emphasized that this collaboration is not only about producing superior frames but also about building a scalable and secure domestic supply chain that reduces reliance on foreign sources.
By sourcing steel from a regional ecosystem, Origami Solar is able to eliminate supply chain risks, reduce emissions, and tap into important domestic content incentives. The company is also creating jobs and fostering innovation in the local communities where its plants operate.
The Role of DAC Robotics in Revolutionizing Manufacturing
DAC Robotics plays a crucial role in this collaboration, providing the custom automation systems that streamline the manufacturing process. From corner insertion to frame stacking, banding, and palletizing, DAC Robotics ensures that the production line operates with remarkable precision. Mark Ganninger, CEO of DAC Robotics, expressed excitement about the future of this partnership, noting that their advanced robotics systems will help scale the business as demand grows.
The integration of robotics into high-speed manufacturing has proven to be a perfect match for Origami Solar’s needs. This collaboration highlights the potential for automation to revolutionize the solar manufacturing industry, making it more efficient, cost-effective, and reliable.
Origami Solar's Vision for a Greener, More Secure Future
Origami Solar is not just reshaping the way solar module frames are made, it is also transforming the solar industry by prioritizing sustainability and resilience. By utilizing domestic steel, recycling materials, and reducing greenhouse gas emissions, Origami Solar is helping to decarbonize solar panels and support the U.S. renewable energy market.
With its innovative steel frames, the company is positioning itself as a key player in the U.S. solar industry. As demand for solar energy continues to rise, Origami Solar’s ability to provide high-quality, cost-effective, and domestically produced components will be critical to the long-term success of the renewable energy sector.
Origami Solar’s leadership team, with its extensive experience in developing and scaling renewable energy companies, is committed to driving the industry forward with cutting-edge solutions that deliver both environmental and economic benefits.
