Photovoltaic Module Metal Frame Market - Global Forecast 2025-2030

The Photovoltaic Module Metal Frame Market size was estimated at USD 14.55 billion in 2024 and expected to reach USD 15.57 billion in 2025, at a CAGR 7.30% to reach USD 22.21 billion by 2030.

In 2024, global photovoltaic capacity soared past 2.2 TW, marking a historic acceleration from the 1.6 TW recorded in 2023. This surge represented a record commissioning of over 600 GW of new solar systems, bolstering solar’s share of global electricity consumption to more than 10 percent for the first time and underscoring the technology’s central role in the global energy transition

Metal frames serve as the structural backbone of photovoltaic modules, bearing environmental stresses, from wind loads and snow accumulation to thermal cycling and mechanical handling. Aluminum alloy frames maintain over 95 percent market dominance due to their high strength-to-weight ratio, excellent corrosion resistance, and ease of installation, while emerging steel frame solutions promise enhanced load-bearing capacity, reduced carbon intensity, and end-of-life recyclability that can lower embodied emissions by up to 90 kg per module

The photovoltaic frame landscape is undergoing a paradigm shift driven by material innovation. Advanced aluminum alloys with superior tensile strength and novel high-strength steel variants are enabling slimmer, lighter frames that deliver uncompromised durability, while domestic recycled steel options are rapidly gaining traction for their supply chain resilience and significant carbon footprint reductions

Simultaneously, digital and automated manufacturing processes are transforming frame fabrication. Cutting-edge extrusion lines, precision stamping cells, and robotic welding stations are boosting throughput and consistency, while data-driven quality control systems and digital twins allow engineers to simulate structural performance under extreme weather scenarios, minimizing defect rates and de-risking large-scale deployments

Moreover, policy and sustainability imperatives are reshaping procurement and design. End-of-life recyclability requirements, carbon intensity reporting mandates, and local content incentives are steering investments toward circular supply chains. Manufacturers are collaborating with suppliers and module integrators to co-develop eco-conscious materials, integrate modular tilt mechanisms, and optimize lifecycle assessments, elevating sustainability leadership as a core competitive differentiator

Since 2018, Section 232 tariffs introduced 10 percent duties on aluminum and 25 percent on steel, and these measures were reinforced by subsequent Section 301 and anti-dumping and countervailing duty actions on solar components from China and Southeast Asia. Beginning January 1, 2025, the tariff on polysilicon and wafers doubled from 25 percent to 50 percent, and tungsten duties rose from 0 percent to 25 percent, reflecting a concerted effort to fortify domestic supply chains and address human rights concerns in Xinjiang

These layered tariffs have directly inflated metal frame costs. Each 10 percent rise in aluminum prices translates to approximately a 0.5 cent/W increase in module costs, and steel tariffs of 25 percent have similarly driven up balance-of-system expenses. Solar module prices experienced a 12 percent uptick in Q1 2025 as import duties on cell and module imports surged, exacerbating supply bottlenecks and pressuring project budgets across all segments

In response, downstream players are recalibrating procurement strategies and reshuffling supply chains. While high inventory levels have temporarily cushioned the impact, analysts anticipate that once stockpiles deplete, steel-framed modules sourced domestically and partnerships with regional fabricators will become essential to mitigate tariff risk and shorten lead times. Chinese manufacturers are also relocating portions of production to lower-tariff countries, intensifying global competition for tariff-exempt supply

Over the long term, these tariff regimes are reshaping the competitive landscape. Higher costs are slowing deployment in the near term, but the heightened focus on domestic manufacturing is spurring capacity expansions in U.S. steel frame production and encouraging innovation in material substitutions, positioning the industry to achieve greater resilience and sovereignty in a fluctuating policy environment

The market for metal frames is segmented by material type, with aluminum frames dominating due to their established manufacturing infrastructure and corrosion-resistant properties, while steel frames are rapidly gaining mindshare for their superior load-bearing strength and potential for domestic sourcing. These contrasting material dynamics are driving product differentiation and sourcing strategies.

Design type segmentation reveals a bifurcation between fixed tilt systems, which prioritize simplicity and cost-effectiveness, and seasonal tilt configurations, which enable adjustable angles to optimize energy yield throughout the year. This divergence is influencing frame geometries and mechanism integration, as manufacturers seek to cater to both high-volume utility-scale projects and specialized commercial applications.

Installation type segmentation encompasses floating solutions that demand corrosion-resistant coatings and buoyant structural designs, ground-mounted arrays requiring robust anchoring and high-wind resistance, and rooftop installations where lightweight profiles and aesthetic integration are paramount. Each installation context imposes distinct performance and material requirements on frame designs.

Manufacturing process segmentation highlights extrusion-based frames that deliver continuous profiles optimized for automated production, stamping methods that allow complex cross-sectional geometries, and welding assemblies that offer tailored structural reinforcement. These processes determine not only production efficiency but also frame tolerances and mechanical properties.

Application segmentation spans commercial deployments seeking scalable cost efficiencies, industrial installations prioritizing durability under heavy-load canopies, and residential systems where low visual impact and rapid installation drive frame selection. This application diversity necessitates adaptable frame portfolios to address varied volume demands and performance criteria.

In the Americas, robust policy support and ambitious decarbonization targets have fueled rapid adoption of both aluminum and steel-framed modules. The United States leads with significant investments in domestic steel frame capacity, driven by Section 232 tariffs and incentives from recent climate legislation, while Canada’s market growth has been underpinned by distributed rooftop and agrivoltaic installations benefiting from streamlined permitting.

Europe, Middle East & Africa (EMEA) presents a diverse tapestry of market drivers. Western Europe continues to favor lightweight aluminum frames for commercial rooftop and façade-integrated PV, supported by circular economy mandates that demand high recyclability and low carbon footprints. Meanwhile, emerging economies in North Africa and the Middle East are embracing ground-mounted solar parks, where high-strength steel frames withstand extreme temperature variations and sand abrasion, aligning with large-scale renewable energy rollouts.

In Asia-Pacific, rapid industrialization and electrification agendas have propelled solar PV into utility-scale and floating applications. Markets like India and Japan are deploying fixed tilt ground arrays at scale, often leveraging cost-optimized aluminum frames, whereas innovative floating PV projects in Southeast Asia require enhanced corrosion protection and modular frame architectures. China’s vast manufacturing ecosystem continues to dominate global frame production, though Southeast Asian hubs are emerging as alternative fabrication centers to circumvent increasingly stringent U.S. duties.

Origami Solar has emerged as a pioneer in domestic steel frame manufacturing, forging strategic partnerships with regional fabricators to establish roll‐forming lines in Houston, Texas, and supporting rapid, one-to-two-day delivery cycles that eliminate tariff exposure and enhance supply resilience. In collaboration with module producers like Heliene, Origami’s steel frames have demonstrated superior structural performance and a reduced environmental footprint compared to traditional aluminum alternatives.

Heliene has leveraged these domestic steel frames to expand its bifacial module portfolio, integrating regional sourcing strategies to optimize cost, mitigate geopolitical risks, and meet stringent domestic content requirements. By incorporating Origami’s frames into both 144 HC and 156 HC module platforms, Heliene has delivered modules that balance affordability, sustainability, and structural resilience under extreme weather conditions.

Tracker and racking system providers, notably Nextracker and Terrasmart, are also innovating around frame integration. These firms are fabricating steel structures in‐house or sourcing recycled steel to support tracker and canopy systems, aligning with local content incentives and mandating alloy traceability. Their efforts underscore a broader trend of vertical integration and supply chain localization across the PV metal frame value chain.

Industry leaders should prioritize investment in diversified material portfolios, balancing established aluminum production with emerging recycled steel capabilities to hedge against raw material price volatility and tariff exposure. Strategic alliances with domestic steel fabricators can accelerate capacity build-out and enable rapid response to policy shifts.

Adoption of advanced manufacturing technologies such as automated extrusion, precision stamping, and robotic welding will be essential to reduce unit costs, enhance quality control, and scale high‐strength frame designs. Integrating real‐time data analytics and digital twins into production processes can further optimize throughput and improve predictive maintenance protocols.

Leaders must engage proactively with policy stakeholders to shape favorable end-of-life recyclability standards and carbon reporting frameworks. By demonstrating compliance with sustainability mandates and circular economy requirements, companies can differentiate their offerings and capture procurement incentives.

Finally, diversifying supply chains across multiple geographies, including emerging Southeast Asian fabrication hubs, can mitigate risks associated with concentrated sourcing. Combined with robust inventory management, these actions will help ensure continuity of supply, cost stability, and resilience in a dynamic tariff landscape.

The research methodology underpinning this report integrates comprehensive secondary data analysis with primary qualitative and quantitative research. An exhaustive review of industry publications, academic literature, and regulatory filings established the foundational market framework.

To validate and enrich secondary insights, expert interviews were conducted with key stakeholders across the value chain, including raw material suppliers, module manufacturers, EPC firms, and policy advisors. Additionally, a targeted online survey captured procurement criteria, material preferences, and future investment plans from over 50 solar project developers and integrators.

Data triangulation techniques were applied throughout to reconcile divergent sources and ensure the highest level of accuracy. Segmentation analyses were rigorously tested against real-world case studies, and forecasting assumptions were stress-tested under multiple tariff and material price scenarios.

Quality control protocols included peer reviews by third-party industry experts and iterative feedback loops with practitioners to refine conclusions. This multi-layered approach ensured that the report’s findings are robust, actionable, and reflective of real-time market dynamics.

As photovoltaic markets continue to expand, metal framing solutions remain a critical enabler of solar infrastructure resilience, efficiency, and sustainability. The interplay of material innovation, advanced manufacturing, and regulatory pressures is driving unprecedented transformation across the value chain.

Emerging steel frame technologies, digitalized production lines, and circular economy mandates are reshaping competitive dynamics, while tariff regimes underscore the importance of supply chain localization and strategic diversification. Segmentation insights across material, design, installation, and application reveal both complexity and opportunity for differentiated product offerings.

Regional analysis highlights that no single strategy fits all markets; leaders must adapt to local policy landscapes, climate conditions, and deployment modalities. Meanwhile, partnerships between frame manufacturers, module integrators, and tracker providers are forging holistic ecosystem solutions that deliver end-to-end value.

In this rapidly evolving environment, organizations that align their strategies with these transformative trends will be best positioned to lead the next wave of solar deployment, drive cost efficiencies, and uphold sustainability objectives.

Finalizing strategic insights and comprehensive data on photovoltaic module metal frames requires decisive action. For direct access to in-depth analysis, exclusive market intelligence, and tailored guidance on leveraging emerging material innovations and navigating complex regulatory landscapes, connect with Ketan Rohom, Associate Director, Sales & Marketing. Engage with actionable recommendations, deep-dive segmentation analysis, and nuanced regional assessments that will empower your organization’s next steps in solar infrastructure development. Reach out today to secure your copy of the full research report and stay ahead in the rapidly evolving photovoltaic market.