The 2026 Kiwa PVEL Module Reliability Scorecard reveals a concerning trend, as module test failures have reached record highs for the fourth consecutive year. Data from the Product Qualification Program indicates that 87% of manufacturers and 61% of bill of materials experienced at least one failure. While performance metrics such as energy yields and power loss in specific categories like thermal cycling and damp heat have improved, structural issues remain prevalent. Mechanical breakage and delamination are particularly problematic, highlighting the ongoing tension between rapid industry innovation, cost-cutting pressures, and the necessity for long-term field reliability.
Mechanical stress and hail impact remain the primary drivers of module breakage, while delamination has emerged as a significant concern, affecting 45% of manufacturers. Despite these structural challenges, the industry has seen positive developments in other areas. Power loss has decreased in tests involving ultraviolet induced degradation, potential induced degradation, thermal cycling, and damp heat. Furthermore, energy yields have trended upward, supported by advancements in bifaciality and temperature coefficients. However, light-induced degradation has seen a slight decline, which experts attribute to the rapid expansion of new cell processing facilities.
The latest edition of the Product Qualification Program has expanded its testing scope, introducing a new Top Performer category for ultraviolet induced degradation and updating protocols for hail and static mechanical load testing. These rigorous assessments are designed to simulate extreme environmental conditions, including high humidity and temperature fluctuations. According to Kiwa PVEL leadership, these findings serve as a critical tool for stakeholders to navigate market risks and differentiate product quality. The data underscores that while the sector is achieving higher performance, manufacturers must prioritize robust design to mitigate the rising frequency of reliability defects.
In this year’s assessment, 43 manufacturers earned Top Performer status in at least one category, marking a decrease from the 50 recognized in the previous year. Notably, for the first time, no single model achieved Top Performer status across every category. The list of top-performing companies remains highly fluid, with 13 manufacturers appearing for the first time, while several previously recognized firms were absent from this year’s rankings. To provide further insight into these shifting trends, an updated version of the Scorecard is scheduled for release in November 2026, with additional analysis expected at the upcoming PV ModuleTech USA conference.