Feature: PSA tapes have a bright future in the solar panel industry
As demand for solar power grows, panel manufacturers should consider the many advantages offered by pressure-sensitive adhesive tapes
Once upon a time, solar power was of interest primarily to scientists, tinkerers and homesteaders. But that time has long passed.
Today’s solar industry is enjoying a boom. And as manufacturers look to ramp up production, they owe it to themselves to consider the many advantages of using pressure-sensitive adhesive (PSA) tapes for bonding applications. Let’s take a look at the state of the solar industry and explore the many ways tapes can help transform solar panel design and assembly.
Solar is growing in the U.S.
According to a March 2025 report by the Solar Energy Industries Association (SEIA), the U.S. currently has 235.7 GW of solar capacity. That’s enough to power 40.7 million homes! The fastest growth is in large solar projects, including those at the commercial, community, and utility scales. The average cost of solar is now lower, globally, than other forms of energy, according to the International Renewable Energy Agency (IRENA). Improved storage is making the technology even more feasible for more people.
The solar industry has been boosted in recent years by the Inflation Reduction Act (IRA). Enacted by Congress in 2022, the IRA has been providing tax credits to manufacturers of renewable energy technology. In fact, the solar industry has added 34 manufacturing facilities since the IRA was signed into law, according to an August 2024 report by American Clean Power. Many of these facilities are located in the West and Southeast. But every region of the country can boast of at least some solar panel manufacturing capacity.
Even with the Trump administration’s sharp divergence on many areas of economic and energy policy, there’s reason for continued optimism when it comes to this industry. As we embrace new, power-hungry technologies such as electric vehicles and artificial intelligence, there’s a growing understanding that our future energy demands will require a broad and diverse selection of domestic sources. That includes solar.
Benefits of PSA tapes for solar panel manufacturing
PSA tapes present several attractive benefits to solar panel manufacturing.
Peel-and-stick ease
Peel off the liner and stick the tape in place. That’s all there is to it. And many tapes can be made with repositionable adhesives that allow assemblers to “tweak” placement (or fix mistakes). Tapes also create less mess and may be safer to use than some liquid adhesives.
PSA tapes also lend themselves well to automated application for manufacturers focused on maximum efficiency.
Lightweight
Tapes weigh less than many mechanical fastening systems, contributing to lighter-weight panels. One of the “holy grails” of modern design and engineering, lightweighting brings a range of benefits to solar, such as lower shipping costs and easier handling by installers.
Durability, even in extreme environments
Modern PSA formulas can be fine-tuned to resist extreme temperature swings and exposure to UV, moisture, dust and other contaminants. Many PSAs offer excellent bonding to challenging low-surface-energy substrates such as PE and PP plastic, EVA and Teflon®.
Design flexibility
Finding a spot to punch a hole in a delicate panel to accommodate a nut and bolt can be a challenge. And those holes practically invite water and contaminant intrusion. PSA tapes don’t require any of this, giving manufacturers added flexibility while helping prolong a panel's life.
Proven performance
PSA tapes are used for bonding in many industries, including automotive, aerospace, batteries, building and construction, electronics, and others. Many PSA tapes engineered for those industries are already well-suited to the demands of solar panel design and manufacturing.
Key solar panel bonding applications for PSA tapes
PSA tapes’ track record means manufacturers can be confident in their choice of PSA as a material solution across numerous applications.
Component mounting
PSA tapes can be used to securely mount components on the inside and outside of a panel. The ideal tape for this application is double-coated (adhesive on both sides of a carrier), while a foam carrier can add gap-filling properties.
Component mounting with gap filling is a common application for PSAs across a wide range of industries, including automotive, aerospace, electronics, general industrial and others.
Dielectric protection
Single-coated tapes with electrically insulating films can provide dielectric protection that is crucial in panel design.
Such tapes are already in use in industries such as EV battery. Avery Dennison’s Volt ToughTM tapes, for instance, are available with dielectric breakdown strength options ranging from 3kV to 10+kV.
Cable fixation
Durable and easy-to-use tapes can be used to help organize and secure wiring within a panel.
Tapes are used for this application in numerous industries, including automotive, aerospace, marine, and building and construction.
Edge protection
Tapes can be applied to panel edges and corners to prevent cracking and chipping, protecting the panel during assembly, shipping, installation, and beyond. A stretchable dielectric tape could be ideal for this application.
This is another common application for tapes in many industries. The Avery Dennison portfolio, for instance, includes a dielectric tape that can be stretched up to 700% while still maintaining its performance.
Collaboration is key
As is the case in many industries, solar bonding applications may require highly customized PSA tape solutions. PSA manufacturers such as Avery Dennison can apply their R&D expertise to tweak adhesive chemistries for specific needs, source unique facestock materials, or even produce liners that meet certain requirements.
Tapes are further customized by converters. These experts can die-cut or stamp materials to specific shapes, widths or formats. Converters typically work directly with solar manufacturers to understand their requirements; then with tape manufacturers, if needed, for additional R&D.
A proven solution for solar
PSA tapes are a high-performance, scalable, reliable and versatile bonding solution for solar panels. And it’s a solution that’s been proven over and over again through similar applications in other industries.
The Avery Dennison Solar Portfolio offers a variety of solutions for common solar panel bonding applications. That portfolio is complemented by our R&D capabilities; we welcome the opportunity to work with you to create custom solutions for unique needs. To learn more, visit tapes.averydennison.com/solar.
Jenna Miles is a product development engineer with Avery Dennison Performance Tapes. With more than 10 years industrial experience, she’s responsible for developing products for a variety of applications, including the Solar Panel segment. To learn more about Avery Dennison’s initiative in the segment you can reach her via email at jenna.miles@averydennison.com or on LinkedIn.