Solar energy plays a central role in the transition to low-carbon power, yet an emerging issue is attracting increasing attention. As early generations of solar panels approach the end of their working lives, concerns are mounting about how they are handled once they are removed from service.
Globally, it is estimated that up to 250 million tonnes of solar panel waste could be generated by 2050. Much of this will come from panels installed during the rapid expansion of solar power in the 2000s and 2010s. Many of these panels were designed with durability in mind, rather than repair, refurbishment or disassembly, creating a significant challenge at end of life.
Panels built to last, not to be reused
Most solar panels have an expected lifespan of 25 to 30 years. As large numbers of early installations now reach this point, countries with long-established solar markets are seeing a sharp rise in panels being decommissioned.
The difficulty lies in how panels are constructed. To withstand decades of exposure to the elements, layers of glass, silicon cells and plastics are tightly bonded using strong adhesives. While this design supports long-term performance, it also makes panels extremely difficult to repair or dismantle. Valuable materials such as silver, copper and high-grade silicon are effectively locked inside, even though they could represent significant economic value over time.
Why recycling falls short
Recycling is often viewed as the solution, yet current processes remain limited. Most recycling methods focus on recovering glass and aluminium, which are relatively low in value. High-value materials are frequently lost during shredding and crushing.
Silver highlights the issue. Although it accounts for a very small proportion of a panel’s weight, it represents a large share of its overall material value. During standard recycling, silver particles are dispersed into mixed waste streams, making recovery technically difficult and commercially unviable.
For this reason, extending the life of solar panels through repair, reuse and refurbishment offers far greater long-term benefits. These approaches preserve embedded value, reduce demand for new raw materials and avoid the energy-intensive processes involved in industrial recycling. Their success, however, depends on panels being designed with repair and disassembly in mind.
Designing panels for repair and longevity
A shift in design philosophy is now being called for across the industry. Instead of permanently bonded components, future panels could use modular designs with reversible connections. Frames, junction boxes and connectors could be made removable, while alternative bonding methods would allow glass and cells to be separated without damage.
Standardised components and clearer documentation would further support technicians throughout a panel’s lifecycle. The aim is to create panels that last longer, can be repaired when performance declines and are easier to dismantle responsibly at end of life.
The role of digital tools
Digital technology may also support better outcomes. To repair or recycle a panel effectively, detailed information is needed about its materials, construction and service history. Digital records can provide this clarity.
One example is the Digital Product Passport being developed by the European Union. These passports are expected to include data on materials, repair guidance, hazardous substances and end-of-life handling, with phased introduction planned from 2027.
Digital twins offer a complementary approach. By tracking real-time performance data, they can flag under-performance, maintenance needs or faults, helping owners decide whether repair or refurbishment is viable. Used together, these tools could improve decision-making throughout a panel’s lifespan.
Digital solutions alone, however, cannot solve the problem if panels remain sealed units designed for disposal. Technology delivers meaningful value only when paired with products that are genuinely repairable and designed for circular use.
Looking ahead
The solar industry faces an important moment of choice. Without changes in design and lifecycle planning, the rapid expansion of renewable energy risks creating a future waste problem. Rethinking how panels are designed today offers an opportunity to support both environmental goals and long-term economic value, ensuring that the transition to clean energy remains sustainable in the fullest sense.
Disclaimer: This article is based on publicly available information and is intended for general guidance only. While every effort has been made to ensure accuracy at the time of publication, details may change and errors may occur. This content does not constitute financial, legal or professional advice. Readers should seek appropriate professional guidance before making decisions. Neither the publisher nor the authors accept liability for any loss arising from reliance on this material.
Practice Hook