Share this project

Done

Share this project

Done
Photo original
We are two inventors working to revolutionize the world of small-scale solar panels. Follow our story and make awesome solar things!
Created by

Alex Hornstein

1,174 backers pledged $77,504 to help bring this project to life.

Recent updates

Photos

1b98a5fa957de4536eb9622aa0242c43 original
2296e2158471b0118ed077e05124c017 original
9e0ab01aa4270e3558bd800a9f8be922 original
3c7d86d46e1b1bc455556fa86592ab21 original
26628687fe3ab83e813d4fc1733e3e39 original
02be764e3082e4f7e339e69fd74a77bb original

Hello world

Patrons,

NUMBER FIVE IS ALIVE!!!

Just kidding. Solar Pocket Factory 1 here, standing in for Alex, whose laptop has been consumed by the hybrid beast that is the TSA and the US postal service. People, can't live with them, can't live without them.

For now.

So, a little update is in order. I made my big debut at Maker Faire Bay Area a few weeks ago, and dewy-eyed onlookers seemed to enjoy my mechanical gyrations and freshly-made-as-a-Krispy-Creme-donut-solar-panels!  Oh, to be loved!

A big 01001000 01100001 01101011 01110101 01101110 01100001 00100000 01001101 01100001 01110100 01100001 01110100 01100001 to human friends Nagle, Bilal, Cesar, Marius, Keting, Anuja, and Tito that helped out! You are slow and inaccurate creatures, but kind.

Instructables update: Maddie the Photonic Madagascar Coachroach that runs faster than your cat. Is it just us machines that think this obsession with cats on the internet is bizarre?   

Until next time, yours with open hardware and extruded arms,

the solar pocket factory 1

p.s. Everyone should have received their kits and shields by now (and likely quite some time ago). If not, send an email to hello@solarpocketfactory.com and complain -- humans running the world does make for copious mistakes, does it not?! ha ha ha ha ha ha ha ha

  • Image 281680 original
  • Image 281681 original
  • Image 281682 original
  • Image 281683 original
  • Image 281684 original

Traveling abroad in the continental style

We've spent the last week in Hong Kong, working like busy little bees to get the Solar Pocket Factory ready for its Maker Faire Debut.  My flight is leaving in just a couple minutes, and Shawn is coming down with the factory in his luggage in a few days.  It's going to be a good week in San Francisco--I'll be presenting the Pocket Factory this Tuesday evening at the Hardware Innovation Workshop in San Mateo, and we're going to have a great booth next weekend at Maker Faire.  If you're in the Bay Area, come say hi and get yourself some fresh solar panels, hot from the oven!

Now, here is a photo of Shawn eating:

An awesome way to make panels with your kits

Hey there!

Many of you have gotten your Solar Pocket Kits and are raring to start making stuff. I want to share this new method that we worked out for making microsolar panels with a laminator. This is the fastest, easiest way we've found to make panels, and it's well worth checking out, if I do say so myself.

Everything you need is in the kits, except for a desktop laminator that you can get from any office supply store or thrift shop.

Check out the full instructable here, or a 1-minute video below:

As a reminder--if you have questions about making panels or working with the kits, want to share solar ideas ideas show off things you've made with your kits, head on over to the Forum for all things Solar Pocket related.

Shine!

--alex

Solar Pocket Pages 4.25.13: a funny thing happened on the way to the pocket

Good evening, dear pockets.

We shall start with an announcement:

Those of you who got kit rewards should have them or will be receiving them shortly, and Shawn and I thought it would be a good idea to make a forum for people to discuss all things solar. So, we present to you (drumroll, please....), the Solar Pocket Forum!
Both Shawn and I will be reading and posting on the forums. We encourage you all to share your projects, to post and discuss and help one another, and above all, to make wonderful things.

...And now, an update:

It's been quite hard to write with authority about something that we're making up as we go along, but that's the pocket factory story these days. The Solar Pocket Factory has moved into a realm of uncertainty, and Shawn and I are experimenting in real-time with this beast, trying to chart a way through the microsolar murk with a blinky compass and poor visibility.

We got our first full machine making panels on the morning of January of 18th, after an all-nighter hacking on the code and mechanicals that made it work. Three hours after filming the video, we caught a train up to Dongguan to try to sell the machine to a microsolar manufacturer.

Long story short, selling a machine that costs $50,000 is easier said than done. We tried over and over again, but clinching the deal was always a trick. Even more disconcerting was the idea that Shawn and I wouldn't buy a machine for $50k, so we were trying to sell to people who were, well, not-us. This requires an extra degree of sales acumen, and frankly, that's not our strong suit.

Rather than trying to fix the sales, which we didn't like, we decided to muck around with solar panels, which we like very much.  One day in March, Shawn and I were playing around with a laminator, and we happened upon a funny combination of materials: PET film, solettes, EVA and PET film. When we made a sandwich of these materials and ran them through a laminator, we got a solar panel. It was waterproof. It was sturdy. And it worked.

Our current Solar Pocket Factory automates the traditional construction technique for solar panels. The thing is, this is a pretty intricate process--we have to place solettes, coat tabbing in rosin, dispense a certain length of tabbing to connect neighboring solettes and solder the tabbing to the solettes. We can do all this, but each of the steps adds complexity and expense to the machine. What's exciting about the lamination technique is that it's a new process--with this technique, we don't use any tabbing, and we don't solder the solettes. We just have to place the solettes and the end contacts for the panel, and then we run it through a laminator. The pressure of the lamination is enough to hold the solettes in electrical contact. This is a much simpler process, and it means that a machine that builds panels with this process is also much simpler.

Here's an illustrated view of the process:

The astute reader of the Pocket Pages might ask, "wait a second--I thought you tried shingling before! What's different now?"

Well, astute reader, I'm glad you asked. Before, we soldered our shingled solettes together, and this made our panels susceptible to thermal stresses that build up as the panel microscopically expands and contracts as it heats up and cools down. Now, the solettes are pinned together with a lamination, but they are free to slide against one another, keeping those thermal stresses from building.

Here's a more detailed explanation (with pictures!) of the problems with soldered shingling:

Once we had this simple process of shingling and lamination solar panels, Shawn and I started to think about a variant of the Solar Pocket Factory could make these panels. After a bit of doodling, we drew up a machine that we code-named the Basking Shark. This is very similar to the upside-down shingling machine that Shawn shows off in the Science Friday video from ~six months ago. We assemble a shingled panel upside-down onto scotch tape, and then bring in rolls of plastic on either side of the panel and run the whole thing through a laminator to seal it. A continuous strip of working, plastic-encapsulated panels comes out of the end of the laminator, ready to go.

One thing you may notice about this design is a couple little logos on the top right: Creative Commons and Open Hardware. We think of this design as a hackable tool for making and experimenting with solar panels, and we want other people to build off our designs and techniques, add their own ideas into the mix, and continue to share. We yearn to see tons of new ideas around ways to make and use solar panels, and we think a simple, open tool that makes it easy to make lots of solar is a big step in the right direction.

It's not all fancy illustrations, too. These last two weeks have been particularly fruitful ones. We've been up to our elbows in laminators, plastic sheets and solar panels, working out techniques for the perfect lamination, and this ugly tangle of aluminum extrusion and joy is the first Basking Shark prototype:

We still have lots of designing, prototyping and testing to go, but at 5am one morning, after an intense night of hacking, I got the first complete panel placement off the prototype Basking Shark machine. The future is bright!

There's one other big change I want to bring up: I'm going to move out of the Philippines on July 1. I've been in the Philippines for over eleven months, now, and I've come to understand a lot about living and working in the country. One of the main reasons I moved to the Philippines was to be able to work on cleantech projects relevant to the country. I believe that microsolar is a relevant, important technology that can offer a lot to the Philippines, but right now, I'm spending the bulk of my time working on the Solar Pocket Factories that make microsolar, rather than making and distributing microsolar products themselves. At this point in the Pocket Factory's development, most of the people interested in our pocket factories are in the US, China and Europe, we're assembling our latest factories in Hong Kong, and I'm working on the electronics from the Philippines. We are a small team, with limited resources, and we're spread very thin right now. We are reaching a point where we can get not only panels, but accessible pocket factories out into the world, and I want to be able to dedicate the time and effort that the project needs.

Part of my decision is also a personal choice, and that's also important to me.

There are still projects to do in the Philippines, and when the factories are ready, there will be an opportunity to get our microsolar out into the country, but right now, we need to focus on making the machines work and getting them out into the world.

To my friends in the Philippines, to those who helped me move here, who worked with me, advised me, traveled with me, sang beatles songs at 3am, stayed up all night and goofed off with me--marami salamat po.

Slacker Backers!

Dear our backers,

     We love you and appreciate you very much.  Thank you very much for making all of this happen.  

     We're very proud of the kits we've put together, and we want to get them to you.  SO, if you're one of the ~80 slackers who hasn't filled out the address surveys, PLEASE do so, and we'll get your rewards to you pronto.

      A more elaborate pocket factory update is forthcoming.  For now, I'll leave you with a photo from last night's solar hackfest.  Making waterproof solar panels on a desktop laminator!