Case Study: BigBelly Solar cuts material costs by 30% and improves product quality with SolidWorks

Compacting Trash via Clean Solar Power With Solidworks Software

BigBelly Solar, a maker of solar‑powered trash compactors that reduce waste pickups and emissions, faced the challenge of scaling design and production while keeping multiple design partners aligned and cutting material and fabrication costs. To standardize development, enable faster iteration, and bring outsourced designs in‑house, BigBelly Solar adopted SolidWorks software as its CAD platform early in the product lifecycle.

Using SolidWorks software—including sheet‑metal design tools, SimulationXpress and interference detection—BigBelly Solar optimized the compactor design, reduced the number of steel parts by 30%, and ensured better quality control during fabrication. The SolidWorks solution helped deliver the world’s first solar‑powered trash compactor, drove a four‑fold rise in unit orders initially and ultimately a 300% sales increase after the 2007 redesign, while lowering material costs and accelerating product development.

BigBelly Solar

Jeff Satwicz

Product Manager