DALLAS — The automated machinery and bright, clean factory floor wouldn’t look out of place in the solar manufacturing hub of Changzhou, China. But every so often, the pristine industrial order was punctuated by, of all things, carrier robots blasting psychedelic rock as they rolled down the aisles.
T1 Energy runs this half-mile-long factory just 15 miles south of Dallas, where seven parallel manufacturing lines produced more than 20,000 photovoltaic modules on the day I visited in October. After ramping up in the early months of 2025, T1 is on track to produce up to 3 gigawatts this year, but with the systems dialed in and workers operating 24/7, the facility has been running fast enough to make 5 gigawatts in a year, said Russell Gold, executive vice president for strategic communications.
“What the manufacturers here really want, and really need, is just certainty,” said MJ Shiao, vice president of supply chain and manufacturing at the trade group American Clean Power. What they got this year was “policy whiplash,” he said, which has caused the Biden-era drumbeat of clean-energy manufacturing announcements to morph into a chorus of cancellations, per data from Atlas Public Policy.
But T1 nonetheless is staking a claim to homegrown American solar energy and making the case that it’s still lucrative. The firm has plowed ahead this year, signing deals for U.S.-made polysilicon and U.S. made steel frames and preparing to build its own solar-cell fabrication facility.
Gold pointed to the booming demand for solar, which has become the biggest source of new power plant capacity getting built in the U.S. today by a long shot.
“We absolutely believe that it is a great time to be making solar,” said Gold, who came to T1 in May after a career covering energy for The Wall Street Journal. “The main reason is we’re in the middle of this massive trend toward more electricity usage … Solar is the scalable energy resource that can produce the amount of electricity that is demanded today.”
State-of-the-art solar manufacturing in Texas
T1’s facility bustles with robots and people working side by side.
Autonomous units ferry materials around and handle the heavy lifting of pallets stacked high with finished panels. Specialized machines cut cells and string them together with electrically conductive filaments, while others sandwich rows of cells between glass, snap their frames into place, and roll them through a high-temperature curing process.
Today those frames are made out of imported aluminum, but next year T1 will replace them with U.S.-made steel frames from Nextpower, the solar equipment juggernaut formerly known as Nextracker. Dan Shugar, Nextpower’s CEO, had visited T1 shortly before I did; given Shugar’s well-known love for classic guitar rock, technicians reprogrammed the autonomous guided vehicles’ warning sounds with grooves by Santana and AC/DC. (“Because of course, AC/DC — it’s appropriate,” Gold told me.) The sounds stuck around.
The factory was running two 12-hour shifts every day, with workers watching over the robots and stepping in when necessary to correct their work. Signs listed every key notice in English, Mandarin, and Spanish, and the 1,200-person workforce reflected the diversity of the Texas metropolis.
The only production line that wasn’t operating during my visit had been geared toward smaller residential panels. T1 had paused production in response to slack demand, Gold said, and was working to adjust the line to produce panels for the booming utility-scale market instead.
Around the factory, a few clues hinted at a more nuanced backstory than the triumphal, homegrown American solar narrative that T1 leads with. Much of the production machinery sported the logo of Trina Solar, a Chinese company that ranks among the most prolific solar manufacturers in the world. At the end of the tour, we surveyed the warehouse area, where pallets of finished modules awaited shipping in Trina Solar–branded cardboard boxes.
The Chinese company, in fact, built the factory, as part of a wave of foreign investment in U.S. solar panel assembly that kicked off back in 2018, when the first Trump administration levied new tariffs on Chinese imports. Chinese investment in U.S. solar factories accelerated considerably when the Biden administration passed industrial policy that rewarded manufacturers for U.S. production and developers for installing domestically made equipment.
Within two and a half years of Biden signing the Inflation Reduction Act, the U.S. built enough factories to assemble all the panels it needed. The entire supply chain had not been re-shored, but it was well on its way — a remarkable turnaround for a sector long since decimated by cheaper Chinese competition. The lone exception to that collapse was First Solar, which makes a thin-film cadmium-telluride panel, in contrast to the dominant silicon-based photovoltaics; that company, too, has expanded its U.S. footprint, recently completing a factory in Louisiana and announcing a new one in South Carolina.
Even before Trump won his second election, though, bipartisan political sentiment was shifting against Chinese companies’ benefiting from federal incentives, even those that built state-of-the-art factories in the U.S. and staffed them with American workers.
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