U.S. solar cell manufacturer strengthens supply chain with a second multi-year agreement

ES Foundry has recently announced a multi-year agreement to supply 300 MW of U.S.-made solar cells to Bila Solar, an Indianapolis-based manufacturer of ultra-lightweight solar modules. This agreement comes on the heels of ES Foundry’s first GW+ multi-year contract with a leading solar module manufacturer.

Located in Greenwood, South Carolina, ES Foundry produces crystalline bifacial passivated emitter and rear contact (PERC) solar cells, which qualify for the domestic content bonus. This partnership between ES Foundry and Bila Solar signifies a move towards onshoring vital manufacturing processes. By sourcing solar cells produced in the U.S. for domestically manufactured modules, the collaboration enhances the domestic supply chain, ultimately contributing to economic stability and security.

Currently, there is a mismatch in the U.S. solar supply chain: while solar module production exceeds 50 GW, domestic cell production is still in its infancy. The U.S. Solar Market Insight Q4 2024 report by the Solar Energy Industries Association (SEIA) and Wood Mackenzie reveals that the U.S. can now produce enough solar modules to satisfy nearly all domestic demand. However, cell manufacturing has lagged due to its complexity and high costs.

“This agreement with Bila Solar underscores the growing market confidence in American-made solar cells,” stated Ken Johnston, vice president of sales at ES Foundry. “By partnering with an innovative module manufacturer like Bila Solar, we are expanding access to high-efficiency solar products and fostering domestic manufacturing growth. This initiative reduces our reliance on imports and solidifies the U.S. position as a leader in clean energy manufacturing.”

Bila Solar is relatively new to the domestic manufacturing landscape. In 2023, the company announced plans to renovate a 150,000-square-foot facility in Indianapolis, aiming to employ 240 workers once the plant is fully operational. Currently, Bila’s patented ultra-lightweight solar modules are being produced, and the company has recently revealed plans to expand its product line to include conventional 550W glass and aluminum frame modules that will utilize the domestically produced solar cells. Production for this new line is set to begin in May.

The technology behind Bila’s modules was developed in partnership with the advanced materials industry. Mick McDaniel, the general manager at Bila Solar, explained that the idea of replacing glass with specially formulated composites was inspired by the lightweight, durable, and UV-resistant windows used in airplanes. “These same characteristics are ideal for solar panels. The aerospace industry has mastered this technology, and our challenge was to adapt it for the photovoltaic sector in a cost-effective manner that meets solar customer needs,” he said.

Solar developers can take advantage of the Investment Tax Credit’s 10% domestic content bonus by using U.S.-made modules combined with U.S.-made cells, according to ES Foundry. McDaniel emphasized, “With 100% of our products manufactured in Indianapolis, Bila Solar is dedicated to providing high-performance, domestically sourced solar modules. Following the U.S. Treasury’s publication of Safe Harbor guidelines regarding the 10% domestic content bonus credit, we have seen increased interest in U.S.-produced modules that incorporate U.S.-made solar cells. Bila Solar is thrilled to be among the first to offer this product in the marketplace.”

Initial capacity at the ES Foundry facility is 1 GW annually, with plans to scale up to 3 GW by Q3 2025. In a January interview, Alex Zhu, the founder and CEO, shared that the company is looking to integrate HJT technology in future expansions. Currently, there are 160 employees at the plant, with expectations to grow to 500 by the end of the year.

Both ES Foundry and Bila Solar will exhibit at the upcoming Intersolar North America & Energy Storage North America conference, scheduled for February 25 to 27 at the San Diego Convention Center in California.