Implementation of silicone process

Manufacturing/Optics for Solar Applications

Manager:

About the Customer

(confidential – on demand) was a technology leader in the production of large-area optic for solar applications The company produced Fresnel lenses in sizes up to 1.5 m². The company was a start-up with three rounds of investment. Time to market is absolutely critical for start-ups, just as it is for any company with launching a new product.

Testimonial from Сustomer

Situation (Challenge)

Start-ups usually operate in volatile markets. Products need to be adapted to sudden changes in the markets. Company structures need to be highly flexible. In this case, customer demand moved from PMMA as lens material (where the company was a recognized world leader) to silicone-on-glass (SOG). The market change was considered permanent due to certain advantages of SOG. On the other hand, SOG requires production processes very different from those of PMMA. Partners and supply chain are from another industry. In addition, the employees needed to be trained with the new processes and materials. The company formed a task force headed by her CTO, RL. Time frame was set to six months, with a large Chinese customer pressing for readiness.

Solution (Achievement)

The task force began with hiring a chemist providing an understanding of the materials and their combinations. Materials benign to the SOG process were identified. The CTO clarified process steps, and specified matching equipment. Using his network, partners were found. Non-conventional technical solutions were thought of, constructed and installed, in order to reduce typical lead times for machinery from six months to six weeks. Tests were continuously run, with the personal involvement of the CTO, but under the responsibility of the R&D manager, and the chemist. In parallel, the position of production head SOG was advertised. A person with little experience in SOG, but strong leadership and motivational skills was selected just in time for him to accompany the final steps in equipment installation, and training of personnel. Crucially, and proving to be the breakthrough to success was the choice of tooling process. A solution was ingenuously found that made use of the existing PMMA process, and ensured the cost effectiveness of the SOG process. In addition, the solution was patented. It took just under six months to complete the task. The first customer ordered for close to EUR 1m. The contract had been negotiated by the CTO along the way in China, closely matching it to the progress at home.