Walter Yu, P.E., LEED AP

Solar manufacturing process at an Applied Materials plant.

Semiconductor equipment manufacturer Applied Materials entered the solar panel industry in 2006 and made a big splash by delivering their first panels within two years of starting design.

There is an interesting article by the Technology Review that describes the manufacturing process and lessons learned during production.

Known for its work in the semiconductor industry, Applied Materials leveraged their expertise in working with silicon, while used in wafer fabrication (for semiconductor chips), is also a main component of solar panels.

The manufacturing process are produced in the same plants and some of the same equipment used for wafter fabrication. The panels start as a sheet of glass covered in a layer of conductive metal oxide, which is then etched in a similar fashion to silicon wafers for computer chips.

Two coats of silicon are added, and metal is added to serve as the electrical back of the panels. Their edges are then finished and tested with the results attached to each panel.

The lessons learned by engineers is that the product process scales better on larger panel sizes, and the panels themselves are more efficient with more surface area. As a result, the panels were not cut into smaller pieces as previously planned.

One important metric for solar panel product is the lifetime cost per watt of electricity that the panel products. The large panels by Applied Materials average about $3.50 per watt, while their is to reduct cost down to $1.00 per watt within a year after start of production.

Looking to computers to give buildings their brain.

Smart buildings have grown from buzzword to reality as their mechanical systems have grown increasingly automated.

They are called smart for their ability to regular HVAC systems, lighting and even elevator loads as in the case of the newly opened Burj Dubai.

Although smart buildings have come a long way, they are becoming dated in the way their systems transfer data and allowing for upgrades.

An article in the Journal of Commerce points out that designer should look to the Internet on making smart buildings smarter. The concept began with smart grids developed by power utilities that can regulate demand and help stabilize the system during peak demand.

Researchers in the energy field suggest that similar systems should be used for buildings, which is how computers connect and form the Internet. Rather collecting all building systems in one central location be monitored as is the current common practice, sensors can be installed within building systems to communicate to each other to create an intranet of sensors.

Current building design, however, are geared towards centralized systems – hence the terms such as central heating, which are controlled by a thermostat. Adding networking sensors would be prohibitively expensive, and the Journal of Commerce article cites a number of $1000 to install a $1 sensor within centralized systems.

The vision that researchers imagine is where the smart grid providing power to a building will communicate within sensors. Not only will the sensors gather data real-time, they will also transfer data to the smart grid to adjust power loading.

Although this may still be some time away, this concept has upstart the idea of centralizing building system controls and open it up for re-consideration towards truly smart buildings.

While co-working with several friends in the Outer Sunset today, a friend of mine turned me onto Architecture for Humanity, an open-source architecture project placing sustainable design in the hands of those who need it in developing nations.

As Cameron Sinclair  stated in his TED talk (see video), sustainability is not about putting solar panels on expensive houses or buying a Prius, it’s about survival in the developing world.

For most of us living in developed nations, sustainability means being resourceful and reducing our impact on the environment. However, for those living in developing nations, being resourceful is a way of life.

Architecture for Humanity solicits for projects that need to be build and mobilizes designers to design them. The most important feature is that these projects are built and make a difference in the communities that receive them. The organization connects sustainable design with those who most need them.

As a civil engineer, I understand that design may not be available to everybody, especially those in developing nations. Infrastructure projects are often built for those will deep pockets who are able to foot the hefty design fees.

And rather than operating as a true non-profit, Architect for Humanity leverages private industry practice with humanitarian work to advance its cause of building projects to improve the quality of life for those getting by with less.

In conclusion, it’s inspiring to see sustainable design being applied to help those who are less fortunate.