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Solyndra – Where Was The Critical Design Review?

Solyndra’s $570M Solar Failure: How a Critical Design Review Could Have Prevented It

Solyndra once promised to revolutionize solar energy. Their tubular solar module design was marketed with style — a solar ray–emitting logo and the tagline “The new shape of solar.” But behind the branding was a flawed concept that cost U.S. taxpayers more than $570 million.

A Critical Design Review (CDR) — a process that typically costs less than $50,000 — could have flagged the flaws early and prevented this costly engineering failure.

What Is a Critical Design Review?

A Critical Design Review (CDR) is a systematic check of a detailed product design. It ensures that the design:

  • Meets performance and safety requirements

  • Is manufacturable and ready for testing

  • Addresses risks before production begins

The CDR acts as a vital checkpoint in the product design review process. It asks the hard questions before major investments are made. In Solyndra’s case, a thorough CDR could have saved hundreds of millions in wasted taxpayer money.

Solyndra’s Solar Panel Design Flaws

Solyndra claimed its cylindrical solar modules could capture sunlight from all angles without expensive tracking systems. On paper, it sounded revolutionary. In practice, it was flawed:

  • Only a small portion of the curved surface saw direct sunlight at any time.

  • The back side of the cylinder never received sunlight, and no reflective layer compensated for the loss.

  • Compared to flat panels, less photovoltaic material was exposed to peak sunlight.

Flat solar panels already deliver maximum efficiency when the sun is perpendicular. Solyndra’s design added complexity without delivering better performance.

The Cost of Complexity in Engineering

Instead of simplifying, Solyndra layered on extra costs:

  • A second glass tube

  • Encased optical materials

  • Rising manufacturing expenses

At the same time, solar cell costs were already falling. This made the added complexity uneconomical. A cost of poor engineering design lesson: complexity often drives up price without improving results.

The Keep It Simple design principle — a foundation of sound engineering — was ignored.

Could a $50K CDR Have Saved $570M?

Yes. A Critical Design Review would have asked:

  • Does this design outperform flat solar panels?

  • Are the added materials and processes justified?

  • Is this manufacturable at scale and cost-competitive?

The answers would have revealed the flaws immediately. For less than $50,000, a CDR could have prevented $570 million in wasted taxpayer funds.

Lessons Learned from Solyndra

Solyndra’s collapse was not just a business failure — it was an engineering design failure. The lessons are clear:

  • Don’t skip the review process. Critical Design Reviews are cheap compared to the cost of failure.

  • Keep designs simple. Added complexity often means added risk and higher costs.

  • Base decisions on engineering, not hype. Marketing and investor enthusiasm cannot replace rigorous design validation.

Conclusion

The Solyndra case shows why Critical Design Reviews are essential in engineering and product development. For a fraction of the project cost, a CDR could have exposed fundamental design flaws and prevented massive taxpayer losses.

In engineering, the rule is timeless: Keep it simple, validate it early, and never skip the review.

Norman T.  Neher, P.E.
Analytical Engineering Services, Inc.
Elko New Market, MN
www.aesmn.org