Western University Canadian Team Pioneers Polycarbonate Encapsulant for Laminate-Free Solar Panels

Breakthrough in Solar Module Design from Western University Researchers

A team of researchers at Western University in London, Ontario, has published a groundbreaking study introducing a novel polycarbonate encapsulant for solar photovoltaic (PV) modules. This innovation eliminates traditional lamination processes, replacing ethylene vinyl acetate (EVA) and glass with lightweight polycarbonate (PC) sheets. The design promises to transform solar panel manufacturing and end-of-life management by enabling easy disassembly and cell reuse.

Led by Professor Joshua M. Pearce, along with Jahangir Abdullayev and Joshua Givans from the Department of Mechanical and Materials Engineering, the work addresses a critical pain point in the solar industry: recycling. Traditional glass-EVA laminated panels are notoriously difficult to recycle, often ending up in landfills despite their long operational life. This laminate-free approach uses heat and pressure to fuse a 3D-printed PC seal, creating robust modules suitable for distributed, open-source production.

The Growing Solar PV Recycling Crisis in Canada and Beyond

Solar PV adoption is surging in Canada, with installed capacity projected to reach 7.12 gigawatts (GW) in 2026 and grow at a compound annual growth rate (CAGR) of 7.54% to 10.25 GW by 2030. However, this boom exacerbates end-of-life challenges. Globally, most panels are landfilled because delaminating EVA from cells damages the high-value silicon components. In Canada, while regulations are evolving—with federal challenges seeking lifecycle recycling solutions—the economic barrier remains high.

The Western University team's publication in the Journal of Cleaner Production (March 18, 2026) tackles this head-on. By designing for disassembly, their modules allow mechanical separation, preserving cells for refurbishment or reuse. This could extend panel lifetimes beyond 20 years, drastically cutting waste and embodied energy.

Understanding Polycarbonate Encapsulant: Properties and Advantages

Polycarbonate (PC), a high-performance thermoplastic, offers superior impact resistance—up to 250 times that of glass—while being significantly lighter. Unlike brittle glass, PC flexes under stress, making it ideal for building-integrated or vehicle-mounted PV. Its natural UV filtering protects cells without additional coatings, though transmissivity is about 80% versus glass's 95%.

• Mechanical strength: Withstands hail (future iterations needed) and dynamic loads per IEC 61215 standards.
• Lightweight: Reduces installation costs and enables new applications like agrivoltaics.
• Recyclability: Fully thermoplastic, sortable post-disassembly.
• Cost-effective: Prototype at $3.11 per watt using retail materials; scales down with recycled PC.

Compared to EVA, which degrades under UV and complicates recycling, PC simplifies processing—no chemical solvents required.

Step-by-Step: How the Laminate-Free Fabrication Works

The process is elegantly simple, leveraging accessible tools for community-scale production:

1. Position solar cells between two PC sheets.
2. 3D-print a PC seal frame with wire exit notches.
3. Heat assembly to PC's glass transition temperature (~147°C).
4. Apply uniform pressure to fuse seal, encapsulating cells without adhesives or vacuum lamination.
5. Seal wire gaps with ethyl cyanoacrylate.

Prototypes used SunPower monocrystalline cells, achieving IP68-equivalent water resistance—remarkable for a non-laminated structure. Pearce notes, “This design specifically enables disassembly and circular-economy reuse of PV—solving one of the largest challenges to recycling standard EVA-glass laminated modules.”

Performance Metrics: Balancing Efficiency and Durability

Initial tests showed promising results. Single-cell modules produced 2.12 watts under sunny conditions, with open-circuit voltage (Voc) and short-circuit current (Isc) stable within ±5% post-encapsulation. Spectral analysis confirmed 80.38% transmissivity, equating to a 16 kWh loss over 20 years per cell—offset by reuse potential.

The modules passed key IEC 61215 mechanical tests (static/dynamic loads, twist, torque) but need hail improvements. Long-term validation under thermal cycling, damp heat, and UV exposure is next.

Photo by LEDC on Unsplash

Environmental and Economic Impacts: A Circular Economy Win

By enabling cell recovery, this design slashes waste. Canada's solar waste is set to grow with capacity doubling by 2035; innovations like this support federal recycling mandates.Read the full paper. Recycled PC frames further reduce carbon footprints by 90% versus aluminum.

Economically, open-source blueprints lower entry barriers for local manufacturing, ideal for remote Canadian communities. Pearce's FAST group emphasizes accessible tech for sustainability.

Open-Source Revolution: Empowering Distributed PV Production

Pearce, a pioneer in open hardware, releases designs under Creative Commons. This fosters global collaboration, contrasting centralized manufacturing. Western's Thompson Centre for Engineering Leadership & Innovation supports such work, positioning Canada as a hub for sustainable tech.Explore research jobs in sustainable engineering.

• DIY-friendly: Uses RepRap 3D printers Pearce champions.
• Scalable: From single-cell to arrays.
• Community repair: Reduces e-waste.

Canada's Solar Landscape: Research Driving Net-Zero Goals

Canada's clean electricity strategy targets 90-95% non-emitting by 2035, with solar pivotal. Universities like Western lead, from agrivoltaics to recycling. CanREA forecasts 17-26 GW solar by 2035. This research aligns with national priorities, attracting funding and talent.

For students, programs in electrical engineering at Western offer hands-on PV projects. Career advice for research assistants applies broadly.

Stakeholder Perspectives: Industry, Policy, and Academia

Industry experts praise the feasibility; Pearce told pv magazine, “The prototypes reached IP68-equivalent sealing... supporting robust field applicability.”pv magazine coverage. Policymakers note alignment with EPR (extended producer responsibility) pushes.

Academics highlight Pearce's 100,000+ citations in open-source PV, inspiring cross-disciplinary work.

Future Outlook: Scaling Up and Broader Implications

Next steps: Multi-cell modules, hybrid glass-PC for hail, full IEC certification. Potential for BIPV (building-integrated PV) in Canada's cold climates. As Pearce envisions, “Future work... to validate long-term durability.” This could cut PV lifecycle costs 50% via reuse.

For Canadian higher ed, it underscores engineering's role in green transition. University jobs in renewables abound.

Photo by Hermes Rivera on Unsplash

Opportunities in Solar Research and Careers

Western University's model attracts top talent. Pearce's profile—top 0.1% on Academia.edu—shows impact. Aspiring researchers: Pursue faculty positions or postdocs in PV. Rate My Professor for insights. Build your academic CV.

Industry needs experts; check higher ed jobs portal.