Floating Solar Farm

Solar Energy
In short
An in-depth development project from research to detailed design with a focus on functionality, safety, and economies of scale.
What we did

Product Research

Concept Design

Design For Manufacture

Economies of Scale

Phelan Energy
Finished on
October 2020
No items found.
Floating Solar Farm

Conceptual Design

There were two main concepts developed.

One with plastic floats, aluminium frames, and large solar panels,

and one with an all-plastic float grid with smaller solar panels.

Each had their own pros and cons and were researched and explored in depth.

An in-depth development project from research to detailed design with a focus on functionality, safety, and economies of scale.

Solar farms consist of tens of thousands of parts and hundreds of tons of material. As such, every gram of material saved on one part means exponential savings on each solar farm. DMC made extensive calculations and design tweaks to optimize cost without compromising critical strength and durability.

Plastic Parts

The main grid of the solar farm consists of blow-moulded plastic floats connected with injection moulded custom nuts and bolts on each corner. A simple, but effective method of surviving the elements for up to 20 years.

Design for Manufacture

As with every DMC design, ease of manufacturing was a high priority. Working in close collaboration with manufacturers, all the plastic and metal parts were designed up to the last detail to ensure fast, easy, and cost effective manufacturing.

Weight and cost on such a large scale was imperative to get right

The aluminium frame consists of a range of extrusions connected with clamps and bolts. Extensive study and calculations were done to optimize the design of the frame for strength, weight and economy. These three factors were all critical to success.

For any more information on this project, please get in touch and we'll connect you with Phelan Energy.

Selected work

With you every step of the process

We believe in building products that make sense for the real world.

"We have developed more than 10 products with DMC. The team have incredible technical skills and are so easy to work with. They know how to listen, track our meetings, and give us clear project timelines."


Plan properly and set up a strong foundation for your product’s development. Research and initial concept exploration goes a long way in ensuring your product idea is viable.

Ideation and Design

Figure out the function, explore the aesthetics and choose a basic conceptual direction to create solution for your business. Expect sketching, CAD and prototyping in this phase.

Engineering Design

Turn that concept design into a fully functional physical prototype that can be manufactured. It's imperative we test our assumptions in the real world and make sure your design can be manufactured!


Finally, your idea is validated, the product can be mass manufactured, and you're now ready to set up your manufacture partners and begin selling your idea to the world.

Get in touch

Every project is unique and requires it's own plan. Get in touch so we can listen to your needs and draft a plan to build an epic solution.

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