Case Study: Solar Infra, Inc. achieves rugged, climate-resilient solar modules that double frame strength and cut costs with SolidWorks

Extending the Reach of Clean, Renewable Solar Energy With SolidWorks

Solar Infra, Inc., a California solar-module manufacturer, needed to extend solar power into environments previously prohibitive due to wind, humidity, salinity, deep snow and extreme heat, and to improve DC-to-AC inverter lifecycle. To address these challenges, the company used SolidWorks 3D CAD and SolidWorks Simulation for integrated design and analysis, enabling rapid iteration with collaborators including Sandia National Laboratories.

Using SolidWorks, Solar Infra developed the ACE module with an integrated microinverter and a new frame profile that doubled frame strength with only a 4% weight increase; SolidWorks Simulation validated performance under 150 mph winds, 35 ft of snow and 130°F conditions. The project delivered measurable impact: about $100,000 saved in prototyping, a 25% reduction in manufacturing/operating expenses, extended inverter life from 10 to 25 years, and expanded deployment into previously off‑limits environments.

Solar Infra, Inc

Jason Strauch

Engineering Analyst