Claire WhitakerBy Claire Whitaker

Updated November 2026

Learning how to make model solar panels is a practical way to understand how photovoltaic cells turn sunlight into electricity. In this guide, you will build a small working panel from solar cells, connect them in series and parallel, seal them against moisture, and test the output with a multimeter. The whole project usually takes an afternoon, and it works well for classrooms, science fairs, or a hands-on introduction before you tackle a full rooftop array.

Gather Your Materials and Tools

Model panels use small solar cells rather than the full-size modules found on homes. Most builders start with a handful of cells rated around 0.5 volts each, a sheet of plexiglass or thin plywood for the backing, and a bus wire or tabbing ribbon to link the cells together. You will also need a soldering iron, flux, a multimeter, a small clear sealant, and a clear cover sheet.

Shopping for one? See our guide: Solar Panel System for Home Installation: 6 Best Options Compared (2026).

  • 6 to 10 small solar cells (check the rated voltage and current on the datasheet)
  • Tabbing wire and bus wire, sized for the cell contacts
  • Soldering iron, rosin flux, and solder
  • Rigid backing board, such as acrylic or plywood, cut to the size you want
  • Clear silicone sealant or epoxy for edge sealing
  • Digital multimeter for voltage and current checks

Wire the Cells in Series and Parallel

Series wiring adds voltage. Connect the front of one cell to the back of the next, so six cells rated at 0.5 volts each produce roughly 3 volts under full sun. Parallel wiring adds current, which matters if you want more amps to charge a small battery. Most beginners start with a single string of cells in series because it is easier to solder cleanly and troubleshoot.

  1. Lay the cells face-up on the backing board with about 3 mm between them.
  2. Cut tabbing wire to about twice the cell length, plus a few centimeters for the bus.
  3. Apply a small amount of flux to each contact and tack the tabbing wire to the front silver busbar of one cell.
  4. Run the wire to the back contact of the next cell and solder it in place. Repeat down the string.
  5. Solder the final positive and negative leads to a short length of stranded wire for testing.

Work quickly with the iron. Overheating a cell can crack it or lift its contacts, so keep each joint under a few seconds of heat.

Seal and Mount the Panel

Once the wiring is complete, lay a clear cover sheet over the cells and seal the edges with silicone or epoxy. Leave the lead wires exiting from one side so you can connect a meter or load. Let the sealant cure fully, which usually takes 24 hours, before you move the panel outdoors. A sealed panel resists dust and humidity, which otherwise degrade cell performance over time.

Test Your Model Panel Output

Take the panel into direct sunlight, ideally between late morning and early afternoon, and point it squarely at the sun. Set your multimeter to DC voltage and measure across the leads. An open-circuit reading near the sum of the individual cell voltages means the string is intact. To measure current, switch the meter to DC amps and place it in series with a small load, such as an LED or a small motor. Record both readings at a few different angles to see how tilt affects output.

Common Mistakes to Avoid

  • Overheating cells during soldering, which can crack the silicon.
  • Reversing polarity, which can damage the cells and wiring.
  • Skipping flux, leaving weak joints that fail after a few days.
  • Testing in shade or on a cloudy day, then assuming the panel is faulty.
  • Leaving edges unsealed, allowing moisture to reach the contacts.
  • A temperature-controlled soldering iron helps you avoid overheating delicate cell contacts. View on Amazon
  • A digital multimeter lets you check open-circuit voltage and short-circuit current on each step. View on Amazon
  • Solar tabbing wire, sized for standard cell busbars, keeps your joints consistent. View on Amazon

FAQ

Can I build a model solar panel without soldering?

You can use conductive adhesive tape or copper foil tape to connect cells, which avoids the iron entirely. Output and durability are usually lower than with soldered joints, though.

How much voltage should a small model panel produce?

A string of six cells rated at about 0.5 volts each should show roughly 3 volts open-circuit in direct sun. Readings drop noticeably in shade or on overcast days.

Is a model panel safe to build at home?

Model panels operate at low voltage and are generally safe, but soldering involves heat and fumes. Work in a ventilated area and wear eye protection. If you plan to connect your build to household wiring, consult a licensed electrician first.

Conclusion

Building a model panel gives you a clear, hands-on look at how series wiring, sealing, and sunlight affect electrical output. Once your small panel reads correctly in sun, you can apply the same principles to larger projects. For readers ready to move up, our guide on How to Make Your Own Solar Panels: A Step-by-Step Guide for Homeowners covers the next steps.

Ready to choose one?

Claire Whitaker

About Claire Whitaker

Claire Whitaker is part of our editorial team and reviews and edits our home solar guides, checking product details against manufacturer specifications and owner feedback.