DOI: 10.12688/openreseurope.23954.1 ISSN: 2732-5121

Introducing a novel approach to certifying integrated photovoltaic product families using semi-fabricates

Nikoleta Kyranaki, Alvaro De Gruijter Eguiluz, Dominika Chudy, Aldo Kingma, Rémi Aninat, Andreas Haller, Ruben Roldan, Marcello La Rosa, Claudio Castellan, Jasper Klomps, Fabio Parolini, Anna Šikyňová, Julien Thiry, Xavier Sahyoun, Arnaud Morlier, Roland Valckenborg, Michaël Daenen
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Background The building-integrated photovoltaics (BIPV) market is expanding, but adoption remains constrained by high costs and complex certification. These issues arise from highly customised designs, varying in shape, size, colour, and materials, driven by regulations, construction needs, and aesthetics, often requiring costly manual production. The Horizon Europe project Mass-Customisation 2.0 (MC2.0) addresses this by introducing PV “semi-fabricates” (SFs): automated, partially finished components tailored to specific BIPV applications. SFs enable flexible design while allowing manufacturers to complete final products through automated processes. The project also tackles certification gaps, as current schemes are not suited to mass-customised BIPV solutions. Methods To address this, we propose a workflow beginning with a review of PV standards, BIPV guidelines, construction norms, and national construction regulations, supported by IEA-PVPS Task 15 insights and input from standardisation experts and insurers. In the proposed methodology, product requirements are analysed to define SF and product families, followed by Failure Mode and Effects Analysis (FMEA) at SF, product, and interface levels. Based on identified risks, relevant norms are selected and, when relevant, new test sequences are designed. Results SFs often lack junction boxes or mechanical supports, making full PV certification impossible. Certification at the SF level is feasible only with representative attachment scenarios; otherwise, it must occur at the end-product level. Applying complete PV certification to niche BIPV products, where volumes are relatively small, can be unnecessarily costly, especially where PV and construction regulations overlap. Conclusions The proposed approach enables identification of appropriate certification pathways and targeted testing strategies, reducing unnecessary burden. Further work should harmonise PV and construction standards, develop modular test sequences, and engage insurers and regulators.

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