Introduction to New Frame Materials
The NX CoreFrame module frames are produced from steel coils and involve over 50 bending steps during manufacturing. These frames are designed to be a direct replacement for existing aluminium frames, requiring no changes to current factory processes.
Aluminium’s Dominance in the Market
Aluminium has been the traditional choice for module frames, with the 2026 International Technology Roadmap for Photovoltaics report from the VDMA predicting that 92% of modules will feature aluminium frames by 2025. Despite the emergence of alternative materials, aluminium is expected to maintain a 74% market share by 2036.
Forecast for Steel and Other Materials
According to VDMA, steel frames are projected to capture approximately 15% of the market over the next decade, while glass composites may achieve a 5% share. The report indicates that frameless modules will continue to serve specific applications.
Quality Concerns and Demand for Steel
Nextpower, a US-based company, is responding to quality issues associated with aluminium frames by increasing production of its roll-formed steel frames. The company acquired Origami Solar in 2025 and has secured large-scale supply agreements with several US module manufacturers. Jenya Meydbray, vice president for advanced steel frames at Nextpower, highlighted that stronger frames could address structural weaknesses in certain project sites.
Geopolitical Factors Influencing Material Choice
The geopolitical landscape also impacts the choice of materials, as aluminium production is heavily concentrated in China, making it challenging to establish alternative sources. In contrast, steel production is more widespread, allowing manufacturers to leverage local resources and meet domestic content requirements for tax incentives.
Glass Composite Materials as an Alternative
Glass composites are being explored as another alternative to aluminium. René Moerman, founder of Xilia Group, is developing a glass fibre reinforced polyurethane material that is lighter and potentially cheaper than aluminium. This material could significantly reduce manufacturing emissions, making it appealing for compliance with the EU’s Carbon Border Adjustment Mechanism.
Challenges and Opportunities for Composite Frames
Despite the advantages of composite frames, challenges remain in demonstrating their long-term performance, particularly regarding UV exposure and fire safety. However, Xilia’s frames have received TÜV certification and have shown resilience in various tests. Some manufacturers are cautiously trialling composite frames for specific projects, particularly in coastal areas where corrosion resistance is crucial.
Conclusion: The Future of Module Frames
While aluminium continues to dominate the market due to its established performance and reliability, the growing interest in steel and glass composite frames indicates a shift towards more diverse material options. These alternatives may not need to replace aluminium entirely but could provide enhanced value in specific applications, particularly as the industry adapts to changing market demands and regulatory environments.
Source: pv magazine Global
