861: 1 in 5 Solar Panels Are Failing — Here’s Why

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1 in 5 solar panels are failing—and it’s not because of hail.

A quiet reliability crisis is cracking open across the industry, and it starts with glass.

In this eye-opening conversation, Nico Johnson sits down with Tristan Erion-Lorico (Kiwa PVEL) and Dr. Teresa Barnes (NREL) to uncover why glass breakage has become the #1 cause of solar module failure. Backed by PVEL’s latest reliability data, they expose how design shortcuts, material stress, and quality-control lapses are pushing failure rates to an alarming 20%.

You’ll learn:

🔹 Why “tempered” glass isn’t always truly tempered

🔹 How glass is allergic to metal, actually

🔹 Why thinner, lighter glass can mean bigger, costlier failures

🔹 What manufacturers, EPCs, and buyers must do now to prevent losses

If you build, buy, or bank on solar panels, this episode could save your next project from shattering—literally.

Get your Solar Fight Night tickets before they're gone: https://tinyurl.com/522wf8v3

Also check out Renewables UnWind Las Vegas: https://tinyurl.com/2ea2c6k3

And don't forget about the pickleball games: https://tinyurl.com/p9h5nv42

If you want to connect with today's guest, you’ll find links to his contact info in the show notes on the blog at https://mysuncast.com/suncast-episodes/.

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Remember, you can always find resources, learn more about today’s guest and explore recommendations, book links, and more than 730 other founder stories and startup advice at www.mysuncast.com.

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You can connect with me, Nico Johnson, on:

Twitter - https://www.twitter.com/nicomeo

LinkedIn - https://www.linkedin.com/in/nickalus