Manufacturing Today Issue - 244 January 2026 | Page 188

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Founded in 1988, PowerFilm, Inc( PowerFilm) began its journey as a research organization in Ames, Iowa. The company was established with the goal of developing new solar materials capable of producing clean energy from the sun using a low-cost roll to roll manufacturing process and was initially supported by the Department of Energy.

The founders soon created a unique composition of fine solar film, designed specifically for flexible substrates using amorphous silicon. Once the material was perfected, the PowerFilm team went on to design and build the specialized manufacturing equipment required to scale production and commercialize the technology.
The company kept its research, development, manufacturing equipment design, and manufacturing activities inhouse, building a self-sustaining network of advanced equipment and machinery.
As President, Daniel Stieler, reveals:“ We have our own people working across every aspect of the business. From production to advancement and innovation, everything is conducted in-house by the PowerFilm family.
“ Our amorphous silicon product is manufactured as a large-scale roll, using one-to-two-mil polyimide as the backing for our solar film. A standard roll is 33 centimeters wide and approximately one kilometer long, which means our manufacturing process is designed specifically for high-volume production.”
With solar technology at its core, PowerFilm Solar offers solar power solutions across a range of applications and sectors. As Daniel confirms:“ You can find application specific solar modules in both military and commercial applications. For example, we make products for applications ranging from flagpole lights and IoT devices to autonomous sea vehicles and semi-trucks.
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