Auto-Layup And Bussing Adapt To Evolving Module Designs
Key takeaways:
Auto-layup systems must accommodate diverse module formats, customized spacing, and application-specific designs beyond standardized layouts
Multi-cut cell designs increase complexity at the bussing stage, requiring more advanced series-parallel configurations
Suppliers are responding with integrated and highly programmable layup-bussing platforms to improve flexibility across changing module technologies
Auto-layup and auto-bussing are fundamentally automation-oriented processes. However, these stations warrant special attention compared to other ‘pure’ automation tools, as they are particularly sensitive to changes in module technologies and formats. With the shift toward more advanced module designs – such as zero-gap layouts and modules developed for nontraditional applications – layup systems increasingly require greater adaptability. At the same time, approaches such as multi-cut cell formats place higher emphasis on the auto-bussing step, which must execute more complex series-parallel electrical configurations.
In response, some equipment suppliers are now offering integrated solutions that combine auto-layup and auto-bussing into a single platform. Given the close interdependence between these 2 processes, we discuss the key technology trends across these solutions.
As module designs continue to diversify, auto-layup systems are increasingly required to support a much wider range of formats. According to Mondragon, layup is no longer defined by a small set of standardized configurations. There are different variants of the module formats with varied sizes of cell strips, emerging flexible and glass-free modules, and application-specific designs such as Agri-PV and BIPV. In addition, customized spacing between strings and cells, which are often application-specific, is becoming more common. In this context, Mondragon notes that optimization is no longer focused solely on minimizing €/W. Rather, there is increasing emphasis on functionality, integration, and application fit, particularly for niche and nonmainstream use cases.
From a different perspective, ConfirmWare views auto layup as a relatively mature process in terms of core technology. The company sees limited fundamental change at the equipment level, apart from ongoing efforts to reduce machine footprint and improve integration with downstream auto-bussing systems.
In contrast, auto-bussing is emerging as a more dynamic area of development. ConfirmWare highlights that the widespread adoption of multi-cut cell formats has a direct impact on bussing requirements. As string counts increase and module circuits become more complex, traditional bussing approaches are no longer sufficient. Multi-cut designs fundamentally alter the series-parallel electrical configuration, requiring corresponding adjustments in bussing schemes to ensure electrical consistency and performance.
Mondragon similarly points out that increasing demand for highly flexible and easily programmable bussing systems, as bussing can no longer be treated as a fixed or secondary process step. With rising string counts and more complex module layouts, bussing systems must be capable of rapidly adapting to new module recipes, often with minimal mechanical modification.
The text is an edited excerpt from TaiyangNews’ latest Market Survey on Solar Module Production Equipment 2026, which can be downloaded for free here.
