A landmark partnership between Minnesota-based Heliene Inc. and California startup Origami Solar is poised to disrupt the solar energy market. By April 2025, they plan to launch the first domestically manufactured steel-framed solar modules in North America. This move not only challenges aluminum’s six-decade dominance but also reflects a broader push to reduce reliance on foreign materials, lower costs, and reinforce U.S. energy resilience.
Steel as a Strategic Material for Solar Frames
For over 60 years, aluminum has been the default material for solar panel frames due to its lightweight and corrosion-resistant properties. However, the U.S. currently imports 90% of its aluminum, with China accounting for the majority of global supply. Steel, by contrast, offers key advantages: it is stronger, more cost-effective, and fully available through domestic supply chains. Origami Solar CEO Gregg Patterson points out that “foreign material dependency undermines long-term energy stability.”
From a structural standpoint, steel also opens new opportunities for solar canopy and carport systems—applications where strength and durability are critical. With rising demand for solar-integrated steel structures in both urban and industrial environments, this shift marks a significant alignment between material innovation and construction resilience.
Reshoring Solar Supply Chains Through Domestic Steel
The partnership aligns closely with the U.S. Inflation Reduction Act’s (IRA) emphasis on clean energy manufacturing within national borders. Rising aluminum tariffs and fluctuating global prices have exposed supply chain vulnerabilities. In contrast, the steel industry in the U.S. offers a stable and vertically integrated network—from steel mills to fabrication facilities.
“All stages of production—from raw material to frame assembly—now happen domestically,” says Patterson. This reshoring also supports broader growth in prefabricated steel structures, especially in solar-ready infrastructure such as modular utility stations and containerized solar energy units, where localized sourcing improves deployment speed and logistics.
Economic Resilience and Renewable Energy Security
Steel frames are not just an economic choice—they’re a strategic one. With solar energy now responsible for 50% of new electricity generation in the U.S., relying on imported components creates long-term risk. Patterson emphasizes, “Energy security is national security,” referencing the lessons learned during pandemic-related supply chain disruptions.
Origami’s foldable steel frame design addresses common concerns about weight and shipping costs, while outperforming aluminum in durability tests under extreme weather. These frames are already being considered for federal infrastructure and utility projects, particularly those complying with “Buy American” procurement mandates—an area where pre-engineered steel components offer a clear advantage in modular deployment.
Setting a New Standard for Structural Solar Innovation
Despite some skepticism about steel’s suitability, year-long testing has demonstrated its performance and longevity. Heliene CEO Martin Pochtaruk describes the innovation as “a leap toward energy independence.” Beyond cost savings, these frames are engineered for longevity, making them well-suited for integration into large-scale modular solar structures, from ground-mounted farms to elevated carports in commercial zones.
This transition also complements emerging trends in solar-powered buildings, where structural framing, photovoltaic support, and prefabricated elements are increasingly unified. In this context, steel frames are more than a replacement—they’re a building block for scalable, sustainable infrastructure.
Conclusion: A Structural Shift Toward Energy Independence
The upcoming 2025 deployment of steel-framed solar modules marks more than a materials change—it represents a foundational redesign of America’s renewable energy infrastructure. By localizing both supply chains and manufacturing jobs, this initiative strengthens national energy security and supports the broader adoption of prefabricated solar-integrated structures.
In particular, steel’s strength and load-bearing capacity make it ideal for solar canopy and carport systems—applications where durability and structural integrity are essential. As urban areas and industrial zones seek scalable solar solutions, steel offers the framework—literally and strategically—for a cleaner, more resilient energy future.
