Power from the Sun
The solar array is the primary energy-harvesting system of a solar car, responsible for converting sunlight into electrical power to charge the battery pack and supply the vehicle’s motor and auxiliary systems. Because the output performance of the array directly determines the car’s driving range and cruising speed, a well-engineered array is essential for success at competition.
Our array is composed of SunPower Maxeon C60 monocrystalline solar cells. These cells were selected for their high efficiency, back-contact architecture, and strong thermal performance. By relocating all current-collecting gridlines to the rear of the cell, the entire front surface is exposed to sunlight, increasing light absorption and eliminating shading losses seen in traditional front-contact cells. This design enables greater energy capture per unit area, which is a critical advantage when working within the 6 m² array limit imposed by the American Solar Challenge.
A major focus of our current work is electrical characterization of each individual cell. Since the cells within a subarray are connected in series, the current of the entire string is limited by the lowest-performing cell. Thorough characterization ensures that only well-matched cells are grouped together, allowing us to maximize array efficiency and avoid power bottlenecks. We are also collaborating closely with the mechanical and aeroshell subteams to determine the optimal subarray layout. The array will be divided into multiple 2×3 removable panels that must contour to the aeroshell while respecting structural constraints, driver egress paths, and aerodynamic requirements.
Looking forward, our next major challenge will be encapsulation. SunPower cells are thin and fragile, and must be shielded from vibration, debris, moisture, and handling damage without compromising optical performance. Our current plan is to encapsulate the cells using anti-reflective EVA film, providing both environmental protection and high light transmission to preserve efficiency. This encapsulation step will be critical in ensuring long-term durability and race-readiness under real-world conditions.
With individual cell testing underway and array layout in development, the next phase will center on prototyping subarrays, encapsulation trials, and electrical integration. Completing these milestones will allow us to validate performance, finalize mounting strategies, and begin full-system fabrication. The continued collaboration between the electrical and mechanical teams will be key to delivering a high-efficiency, reliable solar array that maximizes our energy efficiency and enhances our competitiveness on race day.
