New QCells plant doubles current US capacity to make solar cells

Qcells has officially begun commercial production of silicon solar cells at its factory in Cartersville, Georgia, the company said Tuesday. That factory is the largest of its kind in the country — and a long-awaited boost to the U.S. solar supply chain.

For five years straight, the U.S. power sector has built more solar farms than any other kind of power plant. In 2022, the Biden administration crafted industrial policy to ensure as many of those solar panels as possible were made in America. Previously, the U.S. solar manufacturing base had withered in the face of stiff competition from China — but the industrial revival effort worked. In just a few years, the U.S. has opened up enough factories to assemble nearly 70 gigawatts of finished solar panels, according to the Solar Energy Industries Association.

That’s well beyond what the U.S. installs in a year, but production of the cell — the high-value component that converts sunlight into electricity — has lagged far behind.

Previously, just three other companies made the component in the U.S.: Suniva can produce 1 gigawatt at its cell factory in Georgia, and ES Foundry and Silfab each can make 1 gigawatt in South Carolina. In a few months, Qcells will be able to manufacture 3.3 gigawatts at its cell factory, which would more than double the current operational U.S. solar-cell capacity.

Qcells, once a German solar cell maker and now a subsidiary of Korean industrial giant Hanwha Group, first announced the Cartersville project in early 2023, pledging to colocate production of four components of the solar supply chain: silicon ingots, wafers, cells, and modules. The module lines went live in 2024. The full facility was originally supposed to open that year, but it took longer to calibrate those more complicated processes. Currently, the full 3.3-gigawatt production of the four solar components is slated for the third quarter.

Another 22 gigawatts of cell capacity is under construction across the U.S., per Solar Energy Industries Association, though that figure is constantly evolving. On Monday, Japan-headquartered Toyo said it would spend $357 million to add 1.5 gigawatts of cell production at its Houston module-assembly plant. ES Foundry is working to expand its factory to 3 gigawatts by year’s end. T1 Energy is building a cell fab outside Austin. Additionally, First Solar’s U.S. factories produce up to 14 gigawatts of cadmium-telluride thin-film panels, which generate electricity without needing silicon-based cells.