Volume 61

Cost-Effective Manufacturing of Polymer-Based Heat Absorbers for PVT Technologies: A Comparative Analysis of Vacuum Forming and Extrusion Processes Kushal Reddy Narendra Babu, Iván Acosta-Pazmiño, Damu Murali, Abel Climente Garcia

Abstract

Polymer-based absorbers offer a lightweight, corrosion-resistant alternative to metals in Photovoltaic-thermal (PVT) and solar thermal collectors. However, their production method is critical to cost, scalability, and performance. This study compares two polymer processing methods, namely vacuum forming and extrusion, by analysing data from systematic qualitative interviews with industry experts and researchers, as well as quantitative production data collected from two European manufacturers. The results indicate that extrusion would be the superior option for commercial- scale deployment due to its higher throughput and reduced environmental impact per unit. In contrast, vacuum forming is more suitable for prototypes and small production runs, particularly when more complex designs are needed. The findings of this study contribute to the strategic decision-making framework concerning the development of cost-effective and efficient photovoltaic thermal (PVT) absorbers.

Keywords PVT, Manufacturing, Polymer heat/thermal absorbers, Vacuum forming, Extrusion