APPEAL
APPEAL develops automated processes for the production of building-integrated photovoltaics in small batch sizes. The aim is to make façades and additional building surfaces economically viable for solar power generation.
Jan 01, 2026 – Jun 30, 2028
This project is funded by "Europe for Lower Saxony. Co-financed by the European Union."
APPEAL – Production Processes for Custom PV Modules
The APPEAL project develops new approaches for the automated manufacturing of building-integrated photovoltaic modules. The project aims to enable the cost-efficient production of PV modules with variable size, shape, and appearance, even in small batch sizes, thereby unlocking new potential for solar power generation on buildings. The project is coordinated by the Institute for Solar Energy Research GmbH and implemented in collaboration with academic and industrial partners.
Initial Situation and Challenges
Achieving the climate targets in Lower Saxony requires a substantial expansion of photovoltaic capacity. A large share of the future PV capacity is intended to be installed on and within buildings. While roof surfaces are already widely used, façades remain largely untapped, despite offering significantly greater surface potential.
The key challenge lies in the limited economic viability of individually designed façade PV systems. Standard PV modules currently available can only be integrated into building envelopes to a limited extent and often face acceptance issues during planning and construction. Custom-made solutions are technically feasible but remain costly due to manual production steps, low levels of automation, and complex supply chains.
Project Objectives
APPEAL addresses this gap by developing a flexibly automated production chain for PV modules in lot size one. The project aims to improve the technical, economic, and design-related usability of building-integrated photovoltaics, with a particular focus on façades and existing buildings.
Research focus and application perspectives
Technical and content-related focus
Across the entire process chain, the project investigates and demonstrates new solutions:
- automated cutting of glass, films, and façade elements using laser technology
- development of flexible handling and gripping systems for module components with variable shapes and sizes
- automated cross-connection processes without harmful thermal stress on the lamination films
- adapted lamination processes for planar and non-planar modules
- digital interconnection of production steps based on a continuous digital representation of the modules
The processes are implemented in a research and pilot production line and demonstrated as a continuous, fully automated manufacturing workflow.
Significance for the energy transition and industry
By combining photovoltaics with established façade systems, material use, installation effort, and overall system costs can be reduced. At the same time, new architectural applications and additional surfaces for power generation in urban areas become accessible. The project also strengthens regional value creation by addressing production approaches that are not suitable for global mass manufacturing. Companies gain new methods for the flexible production of building-integrated PV modules and can reduce their dependence on standardized imported products.
APPEAL therefore contributes to accelerating the expansion of photovoltaics, advancing automated manufacturing technologies, and positioning Lower Saxony in the growing market for building-integrated photovoltaics.
Funding
