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Purpose -The purpose of this paper is to describe a heating system for the selective inhibition sintering (SIS) process that will produce uniform heat and minimize the polymer powder waste. Design/methodology/approach -This research was conducted in two areas: the first was the production of uniform heat distribution. For this task, a lighting design software was used for the initial heater design. The result was then validated by thermal images, point-by-point temperature measurement, and physical part fabrication. The second area was the minimization of polymer powder waste. For this task, a finger-based masking mechanism was designed, prototyped, and tested. Findings -The lighting design software output illustrates that the square, crossed, and parallel patterns have very low variation and seem to be acceptable alternatives for the heating system pattern. Also, results show that the temperature variation for the ceramic heater is lower (therefore better) than the wire heater. Also, the study reveals that a finger-based masking system design and prototype is very promising from the polymer powder waste-saving standpoint.Research limitations/implications -Owing to the software limitation, radiation is the only source of heat transfer in this research (convection and conduction were not considered). Also, a limited number of patterns were examined for the heater design; this number can be expanded in future research. Originality/value -A new design and development method has been proposed for the heating system for the SIS process that could lead to better heaters and waste-reducing mechanisms for the SIS process and similar applications.

This report describes work performed by Spire Corporation during Phase 1of this three-phase PVMaT subcontract to develop new automated post-lamination processes for PV module manufacturing. These processes are applicable to a very broad range of module types, including those made with wafer-based and thin-film solar cells. No off-the-shelf automation was available for these processes prior to this program. Spire conducted a survey of PV module manufacturers to identify current industry practices and to determine the requirements for the automated systems being developed in this program. Spire also completed detailed mechanical and electrical designs and developed software for two prototype automation systems: a module buffer storage system, designated the SPI-BUFFER 350, and an integrated module testing system, designated the SPI-MODULE QA 350. Researchers fabricated, tested, and evaluated both systems with module components from several module manufacturers. A new size simulator, the SPI-SUN SIMULATOR 350i, was designed with a test area that can handle most production modules without consuming excessive floor space. Spire's subcontractor, the Automation and Robotics Research Institute (ARRI) at the University of Texas, developed and demonstrated module edge trimming, edge sealing, and framing processes that are suitable for automation. The automated processes under development throughout this program are being designed to be combined together to create automated production lines. ARRI completed a cost study to determine the level of investment that can be justified by implementing automation for post-lamination assembly and testing processes. The study concluded that a module production line operating two shifts per day and producing 10 MW of modules per year can justify $2.37 million in capital equipment, assuming a 5-year payback period.