Additive Manufacturing Meets Photovoltaics
In recent years, 3D printing has made the leap from prototype manufacturing to series production. In the solar industry, additive manufacturing also opens up new possibilities – especially for components that were previously cobbled together from standard parts. A prime example: the roof penetration for PV cables.
Why Conventional Manufacturing Reaches Its Limits
Conventional roof penetrations are usually manufactured by injection molding from EPDM or silicone. This has disadvantages:
- High tooling costs require large quantities to be economical
- Adaptations to new requirements take months
- Material mix is limited for complex geometries
- Variants in small quantities are uneconomical
For an industry that is rapidly evolving, this is a problem. New module sizes, altered cable cross-sections, or additional requirements for potential equalization demand flexible manufacturing methods.
3D Printing with TPU: The Best of Both Worlds
NEXCAPE relies on 3D printing with TPU (Thermoplastic Polyurethane). This process combines the flexibility of additive manufacturing with the excellent material properties of TPU:
- High Elasticity: TPU remains permanently flexible and adapts to tile contours
- UV Resistance: No embrittlement due to sun exposure
- Chemical Resistance: Resistant to weathering
- Temperature Range: Works equally well in heat and frost
Advantages of the 3D Printing Process
| Aspect | Injection Molding | 3D Printing (NEXCAPE) |
| Tooling Costs | High (€5,000–€50,000) | None |
| Variety of Variants | Limited by tools | 6 variants easily producible |
| Adaptation Time | Weeks to Months | Days |
| Minimum Order Quantity | Often 1,000+ pieces | From 20 pieces (B2B) |
| Manufacturing | Often Far East | Made in Germany |
Made in Germany: Short Distances, High Quality
NEXCAPE manufactures its roof penetrations in Germany. This means short supply chains, quick availability, and consistently high-quality standards. For solar installers, this has practical advantages: orders are delivered promptly, and a German-speaking contact person is available for inquiries.
Six Variants for Every Need
Thanks to 3D printing, NEXCAPE can economically offer a wide range of products: penetrations for 2, 4, and 6 PV cables, each with and without a PE channel for potential equalization. All variants are available in 105 mm, 125 mm, and 150 mm lengths. This variety would be hardly economically viable with conventional tools.
Future of Solar Components
3D printing will continue to gain importance in the solar industry. Customized components, rapid product adaptations, and sustainable manufacturing without overproduction are advantages that perfectly suit an innovative industry.
Experience the difference – NEXCAPE roof penetrations from the 3D printer: PV cable roof penetrations in the shop
