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Manufacturing Photovoltaic Devices at the Global Solar Factory

Bob visits the Global Solar factory in Tucson, Arizona, to see how they make their unique solar-electric (photovoltaic) devices. Neil Holstad, president of Global Solar, leads a tour of the plant. The factory itself includes many environmentally friendly features, including abundant day lighting, recycled brick fascia, graywater recycling, concrete containing fly ash, rammed-earth garden walls and energy efficient windows. They go inside the ultra-clean plant and see the unique flexible photovoltaic devices. The flexible material allows the devices to be used in many applications, such as the solar shingles used in the Habitat for Humanity project in Yonkers. Robert Wendt, Director of Technical Operations, shows Bob the materials used to make the solar cells and one of the manufacturing machines they invented for producing them.
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Manufacturing Photovoltaic Devices at the Global Solar Factory

  computer-generated transcript - may not be 100% accurate

" Hey before we going to talk about -- takes tell us about your building understand you're about to win. An Award. Yes -- in tomorrow and a lawyer for how green and manufacturing facilities we have here we've incorporated a number of ecologically sound aspects to it. One example is we have daylight in in the production area in the ceilings which brings satellite into workers areas. Now that's spent specifically refers to the kind of skylights that uses mirrors. Stuff yes did it actually reflect extra light down and take some of the heat building and back. When we're getting our building permit for the electrical inspection inspector was actually irritated and it's that we had electricity -- on -- like. Not the -- he was brilliantly stylized those -- exciting -- well you know you can see the H a brick that we have here that's actually recycled pharmacy that was being torn down town they recycle all. Gray water out a building from the drinking fountains and water all the wonderful landscaping we have on site the walls themselves. Actually art house solid concrete that include appliance. Which has been recycled that's. Waste product in the local utility generating electricity and out not only do we recycle it actually makes countries does it add strength to the concrete Dave yeah. And he rammed earth around here yeah in fact the that all the walls instead using traditional materials used rammed earth which just dirt in compact it and making beautiful wall."

" And then of course you've got. I energy efficient windows with bonding over them and lots it's still looks like -- kind of traditional New Mexico or."

" I guess everybody's familiar with the traditional political -- now all right. Yes the vast majority. Anything you'd see out there from solar need you policy of this type and houses made. You melt down Phillips and when it's they had a very very thin wafers. They do a lot of different processes to it when they get down they have very thin fragile cells that are. More fragile and cracker they have the wedge in between they keep the glass and a big rigid and all right it appears heading it yes and."

" But essentially when the sunlight hits these things you'd get electrons bouncing all over the place that will create electrical. Charges electricity and later on that we are well over twenty pounds and now the product that you're making is this."

" Yes we manufacturer instead melting down -- we manufacture this product thousand foot long -- plastic material. That you can actually stand role. And so durable and back that -- we've shot bullets driven -- over it with very minimal. Performance Saturday."

" And it's still functions and Specter of the delta election and they can you explain how you are you make this -- mean what's the first material that use. Nobody can now are portable take material consists actually or layers and each one of those or -- extremely then. We've taught at both on -- carrier plastic that the trail right here. So this is like the substrate -- afraid that 2000 -- armored home. Or -- in the trail that we put on about 120 to act that's starting here so we wanted very. What are the four materials your but he but he made. Those elements here yes they are before materials Bob the first one of them on metal and it followed by copper Indians gallon I. Add insult fight and alas players Indians and oxide. In each one of these players at -- very specific function. The first player all of them is. The positive electrode -- battery it's the first player that's down the way that we put it down as we start with the precursor materials that the molten metal here. And we put it inside the chambers and we deposit on the lamp life process called -- Call one called sputtering. It touches and sparing the way it works is we find negative. Electrical potential that this plate yet and we add -- argon gas. And by are not the adding argon gas. It comes and we'll collides with the target and the tree will come off condense on the for condense -- the -- are and in my guessing that. Some of the machinery behind you is where this actually takes place yet the machine itself of them all of them machine on the did you did you guys develop the machinery here or -- so that you site Robert -- Yeah most of the machines were designed. Like me into my colleagues to I would have expected a much larger. Piece of machinery that yeah they are quite small Bob let's take a look inside look at open its decadent and helpful right. No it's not we'll show -- thing works when it's running it's actually -- back here. So would be yet. The way it works Bob is we have a roller and a top or on the bottom we start by mounting the plastic on the bottom or. Simply -- around series -- roller and and have pulled up and the topple it makes me think of the insides of a camera there that's very much what it's like right as it passes through here instead of starting and stopping like. However it passes through and continuous fashion and passes in front of course our sources you can see inside right now here cute targets. And that's where yours -- in the Clinton is latching on to the that's right back in use -- and I think that's right."

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