The American solar panel subcomponent manufacturing sector is gaining momentum, with the introduction of Made-in-USA junction boxes by Amphenol Industrial Operations (AIO). AIO, a division of Amphenol Corporation known for interconnect systems in harsh environments, is preparing to open a 58,000-square-foot factory in Mesa, Arizona, dedicated to manufacturing junction boxes and their associated connectors for both thin-film and silicon solar panel designs. The facility is expected to commence operations before the end of this year, creating 50 specialized jobs in the solar manufacturing industry.
Mark Farrelly, Business Development Director of Environmental Solutions for AIO, emphasized the significance of this venture. He noted that while the investment in the junction box factory might appear modest compared to the massive spending on new solar cell and panel facilities, domestic junction boxes have become a crucial factor in discussions surrounding manufacturing incentives.
Farrelly stated, "We had 22 meetings with module manufacturers at RE+, nearly all of which expressed greater than 50% interest in [AIO making junction boxes in the United States]. They want to know how fast, kind of chomping at the bit, asking can we deliver this year."
To qualify for "domestic content" bonus credits, solar panels must have 40% of their components made in the USA. Junction boxes significantly contribute to the domestic content calculation.
AIO, a global company with a substantial presence in various industries, is primarily focused on its solar business in factories located in Shenzhen, China; Nogales, Mexico; and Pecs, Hungary. However, as AIO is a business unit of a U.S.-based parent company, establishing operations in America aligns with this global movement to diversify outside of China, especially after the introduction of the IRA.
This new factory in Mesa complements Amphenol's other facilities in the area, concentrating on military and aerospace operations. With an existing presence in the region, the startup process has been swift, and the first products are expected to roll off the assembly lines by the end of 2023.
AIO will focus on two core junction box designs: a rounded unit for thin-film panels and a three-box design for silicon panels. The latter is adaptable across most brands and is commonly used in advanced panel designs. AIO is also ready to accommodate custom box designs as needed.
The junction boxes will be equipped with AIO's H4 connectors, aiming to encourage module manufacturers to return to the H4 family of connectors, known for their dominance in North America.
While junction box production is measured in pieces rather than megawatts, each production line can manufacture 100,000 pieces a month, with the Mesa facility capable of accommodating a dozen such lines, potentially producing approximately 4.8 GW of annual production.
Source: solarpowerworldonline.com