QAZAQ GREEN. A new innovation from Charge Robotics promises to make large-scale solar projects cheaper and faster. The startup, founded by MIT alumni, has developed a system that automates the assembly and installation of solar farm sections, reducing labor costs and accelerating project timelines, MIT reports.

With the cost of solar panels plummeting over recent decades, installation expenses have become a major barrier to widespread adoption. The long and labor-intensive installation process has also emerged as a bottleneck in scaling up solar energy. Charge Robotics aims to change that by introducing portable solar installation factories that can be deployed directly to solar project sites.

These mobile factories automate the assembly of critical solar farm components, including tracks, mounting brackets, and panels. Once assembled, a robotic vehicle autonomously positions the completed sections in their final location, streamlining the traditionally manual process.

“We think of this as the Henry Ford moment for solar,” says Charge Robotics CEO Banks Hunter, who co-founded the company with fellow MIT alumnus Max Justicz. “We’re transitioning from a highly manual installation process to a system designed for mass production. This brings consistency, quality, speed, cost savings, and improved safety.”

The demand for solar energy is skyrocketing. In 2023, solar power accounted for 81% of new electric capacity in the U.S. To sustain this rapid growth, the industry must overcome labor shortages and inefficiencies in solar farm construction.

Charge Robotics faced initial skepticism when presenting its vision to investors and industry leaders. However, in early 2023, the company successfully deployed a prototype system in collaboration with SOLV Energy, one of the largest solar installers in the U.S. The breakthrough proved the system’s effectiveness, leading to $22 million in funding for commercial deployments later this year.

From surgical robotics to solar innovation

Hunter’s background in mechanical engineering led him to work with MIT-founded startups like Shaper Tools and Vicarious Surgical, the latter raising over $450 million in funding. His passion for problem-solving and climate change motivated him to explore opportunities in renewable energy.

Together with Justicz, who has expertise in mechanical engineering and computer science, the duo conducted extensive research into the energy industry. Their findings reinforced that solar power was the fastest-growing and most cost-effective energy source in human history. However, labor shortages and slow installation processes were slowing its expansion.

Their first visit to a large-scale solar farm in California’s Mojave Desert confirmed the challenge: millions of panels being manually installed in repetitive tasks over months.

“We saw thousands of workers assembling identical parts by hand,” Hunter recalls. “It was clear this process wasn’t scalable enough to meet global energy demands.”

Transforming solar construction with automation

Charge Robotics’ solution involves a portable assembly line shipped to construction sites. The system autonomously assembles solar farm sections, ensuring high-quality production and efficiency.

Each completed solar bay spans 40 feet and weighs around 800 pounds. A robotic vehicle transports these sections to their designated locations. While the system automates nearly all mechanical installation steps, the initial process of driving metal stakes into the ground remains manual.

The technology also integrates machine-vision systems to inspect components, ensuring quality control while supporting various panel sizes and mounting systems.

Scaling up for the future

Despite early skepticism, Charge Robotics has rapidly gained industry recognition. The company’s first field deployment proved successful, transforming doubters into believers. “Once people saw our system in action, they got excited,” Hunter says.

Charge Robotics plans to deploy multiple factories at large project sites, potentially operating 24/7 to accelerate construction. By collaborating with solar construction companies, the startup envisions a future where robotic equipment replaces repetitive manual labor, allowing workers to operate and oversee machines instead.

“The biggest limit to solar growth right now is labor,” Hunter explains. “With our system, we can build bigger sites, faster, and with the same workforce by simply deploying more portable factories. This is a fundamentally new way to scale solar energy.”