Manufacturing for Tier 1: What We've Learned Over 10+ Years

Daisy Zhao
Nov 26
3 min read

Updated: Nov 26

Imperial Star Solar’s decade-long history producing for Tier 1 solar brands has delivered invaluable insights into what truly drives quality, reliability, and financial trust in the solar industry. As we prepare to earn our own Tier 1 certification, here’s a closer look at the key lessons and practices that shape our approach today.

Quality Control is a Continuous Process

It starts on the floor: our 2GW Tomball, Texas facility runs 24/7, maintaining strict control over temperature, humidity, and air quality for every assembly run. From the jump—inspecting incoming cells to each of the 50+ AI-enabled checkpoints throughout our 95%-automated line—real-time data and experienced technicians drive a process that doesn’t just find problems, but prevents them. With every panel welded in a rapid 14-second cycle and a facility accuracy rate at 98%, the result is consistent performance you can measure in the field.

The Importance of Supply Chain Transparency

We’ve learned domestic content is non‑negotiable if you want accountability and resilience. Most of our cells and a growing share of components—frames, junction boxes, encapsulant, backsheet, etc.—are sourced domestically, making it simple to document origins, verify certifications, and pass on maximum IRA benefits. With a single digital system monitoring every phase, our customers see exactly what goes into their modules and why it matters.

Scaling Without Compromising Craftsmanship

Tier 1 manufacturing isn’t only about speed. We’ve invested in advanced automation, inline inspection, and hundreds of hours of routine operator training to keep human judgment sharp where it counts. Across four inspection points—stringing, pre-lamination, post-lamination, and final check—AI systems and trained operators review 100% of output, driving a tightly controlled process with scrap rates on some materials below 0.5%.

Builder-First Design and Testing

We go beyond the spec sheet, engineering our modules based on the real-world needs of EPCs and installers. Each batch undergoes rigorous testing, including full IEC 61215/61730 certification, frequent accelerated aging, and extreme weather simulations. We also conduct targeted hail testing, as recently completed for a customer, with sizes from 40mm to 50mm at 30m/s across 11 controlled impact locations. With third-party validation underway through DNV, the result is a module designed to thrive in the field, safeguarding your project timelines and budgets.

Financial Strength and Documentation Matter

More than making quality products, Tier 1 requires financial rigor, bankability, and a clear paper trail. Our decade of Tier 1 manufacturing experience, growing U.S. footprint, and transparent documentation give lenders and project owners confidence that risk is controlled and performance can be validated where it counts: on American rooftops and in utility-scale fields.

Trusted by Industry—AVL Approved

Imperial Star Solar isn’t just talking about quality—we’re proving it daily. We are officially approved on major AVLs like Dividend and Sungage with more on the way as we ramp up our own branded offering. That means builders, project owners, and financiers can trust our modules have met independent industry benchmarks for reliability, quality, and bankability.

Over the coming year, as we move toward formal Tier 1 certification, we’ll keep demonstrating how these lessons and practices translate into real value for American energy projects—today and tomorrow.

Get an inside look at American solar manufacturing. Walk the factory floor, meet the team, and see up close how precision and grit power every Domestic Choice module. Reach out today!