U.S. solar module production reaches the historic milestone of 100 gigawatts

Thus, crossing the 100-GW module production threshold provides a useful vantage point for reflecting on the next phase of domestic U.S. solar manufacturing development—namely, applying similarly rigorous oversight to production metrics for ingots, wafers, and cells, beginning directly at the factory floor. Figure 1: Cumulative U.S. solar PV module production reached 100 GW in Q2 2026—up more than 70% since the Inflation Reduction Act’s implementation at the end of 2022. Reflecting on over two decades as a solar PV market analyst, this article is one I never imagined writing—and certainly never expected, by 2026, to be deeply analyzing factory-level data from over fifty U.S. companies, scouring site-specific output across a nationwide land rush to stake claims throughout the entire solar ecosystem. Twenty years ago, when I first joined Solarbuzz, the landscape was entirely different. Back then, my research was dominated by the thin-film phenomenon. I routinely spent time mapping subtle variations across fifteen or more process-flow iterations—a period during which the U.S. was the undisputed technological driver of that technology. For years, U.S. solar manufacturing felt like an intellectually captivating playground for technical learning—but not a globally commercially significant force. My U.S. solar journey began with visits to manufacturers such as Frederick and Fremont. Over these decades, the geographic center of manufacturing ownership shifted dramatically, and I continuously flew across India, Taiwan, China, South Korea, and Southeast Asia, tracking the industry’s wave of global commoditization. Today, the story appears to have come full circle—I’m back where I started: refocusing my research squarely on domestic U.S. operations, tracking capital expenditures, process variants, and real, company-level production output. Tracking these data points at this moment in history makes the announcement of this milestone feel all the more personal and meaningful. From Global Leader to Industrial Follower U.S. PV manufacturing traces its origins to the earliest commercial era of the solar industry in the 1970s. By 1985, the U.S. had produced and shipped approximately 100 megawatts of PV modules—accounting for nearly all global sales during that period. At their peak, companies like Arco Solare and Solarex generated annual outputs in the mid-megawatt range—modest by today’s standards, yet they were global leaders in solar production at the time. In the 1990s, Japan became the first country to build large-scale PV manufacturing facilities, backed by government and industrial infrastructure—including deep expertise in electronics and manufacturing. Direct linkage to the first subsidized domestic solar end-market enabled rapid growth in Japanese PV module output, ultimately surpassing U.S. annual domestic production by the decade’s end. To capture growth in the U.S. market, leading Japanese solar manufacturers began establishing localized module assembly plants directly within the United States. This overseas manufacturing strategy allowed them to respond flexibly to shifting local-content preferences while minimizing logistics costs associated with module transportation. This move triggered a broader trend, attracting a wave of foreign firms eager to invest in and supply the rapidly expanding U.S. solar infrastructure. Sharp established module manufacturing in Memphis, Tennessee, while Kyocera later assembled modules in San Diego.

The U.S. expands its 'tariff map,' proposing minimum-price tariffs on polysilicon under Section 232

The core beneficiaries of this policy are U.S.-based polysilicon producers—Hemlock Semiconductor in Michigan (a joint venture between Corning and Japan’s Shin-Etsu Chemical) and Wacker Chemie’s facility in Tennessee. In its statement, Wacker emphasized: “Without polysilicon, the next steps in the value chain—wafers and chips, or wafers and solar cells—would be impossible.” Notably, the U.S. Solar Manufacturers Association and bipartisan lawmakers pointed out in comments submitted to the Department of Commerce that, even with tariffs imposed, the industry will still need to import solar products from non-Chinese producers—including Korea’s OCI Holdings (with facilities in Malaysia) and Germany’s Wacker (with facilities in Germany and Malaysia)—until domestic polysilicon, wafer, and cell capacity expands. The 'Achilles’ heel' of U.S. domestic PV manufacturing Since Congress introduced tax incentives in 2022, U.S. solar manufacturing has expanded—but growth has been concentrated primarily in panel assembly. Upstream segments such as wafers and cells remain highly import-dependent, and these segments require longer investment lead times. Several companies—including Toyo, Qcells, Corning, Canadian Solar, and T1 Energy—have announced or launched facilities upstream in the solar supply chain, partly to meet stringent 'Made in USA' requirements tied to federal clean energy subsidies. Yet ramping up capacity takes time. The U.S. policy dilemma lies in balancing support for domestic producers against rising chip and solar panel costs—both of which are in exceptionally high demand amid the booming expansion of AI data centers. Industry groups representing solar developers and semiconductor buyers have warned the government that tariffs could raise the cost of solar power plants and drive up prices for consumer electronics and automobiles alike. Even some manufacturers worry about cascading impacts on demand. 'If costs become too high, projects in the market may begin collapsing,' said Martin Bochtaruk, CEO of panel manufacturer Heliene, which operates a factory in Minnesota. He described the solar industry’s role in chip-centered trade investigations as 'collateral damage.' Accelerated expansion of the 'Section 232 tariff map' Beyond polysilicon, the Trump administration has completed Section 232 investigations and imposed tariffs on automobiles, steel, aluminum, copper, and lumber—and is expected to soon announce findings on imported drones and industrial robots. Additionally, the U.S. government continues investigations into semiconductors, pharmaceuticals, critical minerals, and wind turbines—aiming to rebuild its global tariff architecture. Industry observers note that the U.S. is attempting to pressure China 'through disruptive investigations and actions focused on specific sectors.' This investigation signals that U.S. Section 232 inquiries have extended beyond upstream raw materials to downstream high-tech applications and derivatives—a development warranting close attention. Globally, non-Chinese polysilicon supply is already tight. Research data shows that non-Chinese polysilicon capacity in 2025 totals approximately 199,000 metric tons, of which only one-third is allocated to solar-grade material for PV use; the majority serves the electronics-grade market for semiconductor production.

US Solar Firms Heliene, Caelux Launch Tandem Panel

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Heliene and Caelux commenced commercial production of a tandem solar panel combining silicon cells with advanced materials, achieving 27% efficiency with deliveries starting in 2027.

reuters

2026-11-10

US Solar Firms Heliene, Caelux Launch Tandem Panel

US Solar Firms Heliene, Caelux Launch Tandem Panel

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