Solar Tracker Component Manufacturing Guide (2026)

Tracker Hardware Overview

Which Tracker Components Need Custom Manufacturing?

Single-axis and dual-axis solar trackers contain five categories of precision-manufactured components. Each has distinct material, tolerance, and surface treatment requirements driven by mechanical loads, corrosion exposure, and field serviceability.

Slew Drive Housings

Cast or machined housings for worm gear assemblies. Require bearing bore concentricity ≤ 0.001" TIR, surface finish Ra ≤ 0.8 µm on bearing seats, and corrosion-resistant alloys (316L or duplex 2205) for long-term field service under cyclic loading.

316L SS / Duplex 2205±0.0005"

Torque Tube Couplings

Cylindrical couplings connecting torque tubes across tracker rows. Bore-to-OD concentricity within 0.001" TIR and keyway parallelism to bore axis within 0.001" are critical for uniform torque transmission and minimizing drivetrain backlash.

Galvanized Steel / Duplex 2205±0.001"

Bearing Blocks

Pillow block or flange-mount bearings supporting torque tube rotation. Bore seat tolerance of ±0.0005" and Ra ≤ 0.8 µm surface finish ensure proper bearing preload and prevent premature wear under repeated stow cycles.

316L SS / 6061-T6 Aluminum±0.0005"

Actuator Mounts

Brackets and clevis assemblies mounting linear or rotary actuators to the tracker structure. Bolt-hole positional tolerance ≤ 0.010" and flatness ≤ 0.005" ensure actuator alignment under design wind loads.

6061-T6 Aluminum / Galvanized Steel±0.005"

Pier Caps & Post Adapters

Formed or machined caps interfacing driven piles to torque tubes. Typically sheet metal (0.120–0.250" galvanized steel) or machined plates with ±0.005" hole-pattern tolerances. Must accommodate pile-to-pile installation variance.

Galvanized Carbon Steel±0.005" – ±0.010"

Mounting Hardware

Module clamps, splice plates, mid/end clamps, grounding lugs, and cable tray sections. Laser-cut and formed from galvanized steel (G90) or aluminum 5052-H32. Must meet UL 2703 grounding and structural requirements.

G90 Galvanized / 5052-H32 Al±0.005" cut / ±0.010" formed

Material Engineering

Material Selection for Tracker Components

Material selection for tracker hardware is driven by three factors: mechanical load capacity, corrosion resistance for the target site class (desert vs. coastal vs. tropical), and cost at production volumes. The table below compares the four primary alloy families used in tracker manufacturing.

Material	UNS / Grade	Yield Strength	Corrosion Resistance	Best For	Relative Cost
316L Stainless Steel	UNS S31603	25 ksi (170 MPa)	Excellent (PREN ≥ 24)	Bearing housings, slew drive components — coastal sites	$$
Duplex 2205	UNS S32205	65 ksi (450 MPa)	Superior (PREN ≥ 34)	High-load drivetrain couplings — aggressive environments	$$$
Galvanized Carbon Steel	A36 / A572-50	36–50 ksi (250–345 MPa)	Good (50–100 µm Zn per ASTM A153)	Torque tubes, pier caps, structural brackets — desert sites	$
Aluminum 6061-T6	UNS A96061	40 ksi (276 MPa)	Good (with anodize + powder coat)	Actuator mounts, lightweight brackets — moderate loads	$$

Desert Installations (Low Chloride)

For inland desert sites with low humidity and minimal chloride exposure, hot-dip galvanized carbon steel (A36 or A572 Gr. 50) per ASTM A153 is the cost-effective standard for structural components. Aluminum 6061-T6 with Type III hard anodize works well for actuator brackets and lightweight assemblies where the weight-to-strength ratio matters for field installation.

Coastal Installations (High Chloride)

Coastal sites with salt air demand 316L stainless steel (PREN ≥ 24) as the minimum for drivetrain interfaces. For high-strength applications in aggressive coastal or tropical environments, duplex 2205 (PREN ≥ 34) provides approximately double the yield strength of 316L with superior chloride pitting resistance. All fasteners should be 316L or duplex to prevent galvanic corrosion at joints.

Dimensional Requirements

Tolerance Requirements by Component Type

Tracker components span three tolerance tiers. Over-tolerancing structural parts wastes money; under-tolerancing bearing interfaces causes premature drivetrain failure. Match the tolerance to the function — per ASME Y14.5-2018.

Component Type	Linear Tolerance	Surface Finish	Key GD&T Callouts	Manufacturing Process
Bearing Seats & Shaft Interfaces	±0.0005" (±0.013 mm)	Ra ≤ 0.8 µm (Ra 32 µin.)	Concentricity ≤ 0.001" TIR, perpendicularity ≤ 0.0005"/in.	5-axis CNC + CMM verification
Structural Brackets & Pier Caps	±0.005" (±0.13 mm)	Ra ≤ 3.2 µm (Ra 125 µin.)	Positional tolerance ≤ 0.010" on bolt patterns	CNC milling or laser cut
Formed Sheet Metal (Brackets, Rails)	±0.010" (±0.25 mm)	As-formed or finished	Flatness ≤ 0.015" per 12" span	Laser cut + CNC press brake
Torque Tube Couplings	±0.001" (±0.025 mm)	Ra ≤ 1.6 µm (Ra 63 µin.)	Bore-to-OD concentricity ≤ 0.001" TIR	CNC turning + milling

Engineering Note on GD&T

For tracker drivetrain components, linear tolerances alone are insufficient. Slew drive housings require concentricity, perpendicularity, and true position callouts per ASME Y14.5-2018 to ensure proper bearing preload distribution. Include datum references on your drawings — we can advise on optimal datum schemes for multi-feature tracker parts.

Corrosion Protection

Surface Treatments for Long-Term Outdoor Duty

Solar tracker components live in UV, thermal cycling (−20 °C to 70 °C daily delta in desert), sand abrasion, and salt fog. The right surface treatment matched to the substrate and site environment is what separates long-term performance from premature failure.

Treatment	Standard	Substrate	Thickness	Protection	Design Life
Type III Hard Anodize	MIL-PRF-8625, Type III	Aluminum alloys	0.002–0.003" (50–75 µm)	Abrasion resistance (Rockwell C 60–70), moderate corrosion	Est. 15–25 years (with powder coat overlay, varies by site)
TGIC Polyester Powder Coat	AAMA 2604 / 2605	Aluminum, steel	2–5 mil (50–125 µm) DFT	UV resistance, color retention, corrosion barrier	Est. 10–20 years exterior exposure (varies by UV and climate)
Hot-Dip Galvanize	ASTM A153 / A123	Carbon steel	50–100 µm (2–4 mil) zinc	Sacrificial zinc — self-healing at scratches	Long-term (desert), est. 15–20 yr (coastal) — varies by site
Citric Acid Passivation	ASTM A967	Stainless steel (304, 316L, duplex)	Oxide layer enhancement (no dimensional change)	Restores passive chromium oxide layer	Continuous (inherent to stainless)

Combining Treatments for Maximum Protection

For extreme desert UV and sand abrasion, combine Type III hard anodize (abrasion layer) with TGIC polyester powder coat (UV barrier) on aluminum parts. For steel in coastal environments, consider duplex coating: hot-dip galvanize + powder coat for both sacrificial and barrier protection. Specify coating thickness requirements on your drawing — we verify with a calibrated DFT gauge on every production lot.

CNC Machining

CNC Machining for Tracker Drivetrain Interfaces

Tracker drivetrain machining is fundamentally about geometric relationships — concentricity, perpendicularity, and surface finish for bearing preload. Linear tolerances alone don't define a functional drivetrain interface.

Concentricity for Bearing Bores

Worm bore to output shaft seat: ≤ 0.001" (0.025 mm) TIR
Multiple bearing bores in a single housing: machine in one setup on 5-axis to eliminate fixture-induced misalignment
Use datum A (primary mounting face) and datum B (shaft centerline) to establish geometric control per ASME Y14.5-2018
CMM verification with probe compensation available on production parts

Perpendicularity for Mounting Faces

Mounting flange perpendicularity to shaft centerline: ≤ 0.0005" per inch of length
Critical for slew drive mounting to torque tube — misalignment causes uneven bearing loading and premature wear
Specify on drawing with datum reference to bore axis, not to part edges
Achievable with single-setup 5-axis machining; multi-setup requires fixture qualification

Surface Finish for Bearing Preload

Bearing seat surfaces: Ra ≤ 0.8 µm (Ra 32 µin.) — required for proper race-to-housing contact
Shaft mating surfaces: Ra ≤ 1.6 µm (Ra 63 µin.) for press-fit or interference-fit applications
Seal groove surfaces: Ra ≤ 0.4 µm (Ra 16 µin.) for reliable O-ring sealing against dust and moisture ingress
Measure with profilometer — visual inspection is insufficient for bearing-critical surfaces

5-Axis Strategy for Multi-Feature Parts

Machine all critical datums in a single setup to maintain geometric relationships
Eliminates error stacking from multiple setups and fixture changes
Ideal for worm gear housings where worm bore, output bore, and mounting faces must all reference common datums
Typical cycle time: 45–90 min per part for complex slew drive housings (depends on material and feature count)

Learn more about our CNC machining capabilities

Sheet Metal Fabrication

Sheet Metal Design for Solar Mounting Hardware

Mounting brackets, pier cap adapters, module clamps, and cable trays are high-volume sheet metal parts. Designing for manufacturability — especially when hot-dip galvanizing is the specified finish — saves cost and lead time at production scale.

Bend Radii & Material Selection

Minimum inside bend radius: 1× material thickness for aluminum, 1.5× for galvanized steel
For galvanize-friendly designs: minimum 2× thickness to prevent zinc cracking at bends
Aluminum 5052-H32: best formability for complex bends; 6061-T6: higher strength but requires larger radii
Galvanized steel (G90): 0.060–0.250" thickness range typical for mounting hardware per UL 2703

Hole-to-Bend Spacing

Minimum distance from hole edge to bend line: 3× material thickness + bend radius
Prevents hole distortion during forming — critical for bolt-pattern accuracy on pier caps
For galvanized parts: add 0.010" to hole diameters to account for zinc build-up (typically 2–4 mil per side)
Slot holes (instead of round) in one axis to accommodate thermal expansion at field installation

Galvanize-Friendly Design

Vent and drain holes (≥ 10 mm) in closed sections per ASTM A385 — allows zinc flow and prevents ash entrapment
Uniform wall thickness minimizes differential thermal expansion in the zinc bath (450 °C / 842 °F)
Avoid enclosed pockets that trap zinc — design with open sections where possible
Formed tolerances post-galvanize: ±0.010" (±0.25 mm) — tighter than this is not reliably achievable

Learn more about our sheet metal fabrication capabilities

Development Workflow

Prototype to Production for Tracker OEMs

Tracker hardware development follows a three-gate workflow that balances speed-to-validation with production readiness. Each gate validates specific requirements before committing additional capital.

Gate 1

3D-Printed Fit-Check

Typically 1–3 days

Validate mechanical fit, connector routing, sensor housing geometry, and field assembly ergonomics with 3D-printed models in nylon PA12 or UV-stable ABS.

Physical fit-check models at ±0.1 mm accuracy
Assembly interference identification
Connector clearance and cable routing validation
Field crew ergonomic feedback on assembly sequence

Gate 2

CNC Functional Prototype

Typically 10–15 days

Production-intent materials, production tolerances, and representative surface treatments for field testing and IEC 62817 certification.

Parts in production-intent alloy (316L, duplex, etc.)
Full dimensional inspection report (CMM)
Surface finish verification (profilometer)
Material certifications per ASTM/ISO standards

Gate 3

Production (100–10,000+ pcs)

Typically 3–6 weeks

Full production runs with process controls, in-process inspection, complete material traceability, and certification documentation.

Batch production with SPC monitoring
First article inspection report (FAIR)
Full material traceability (heat lot to part)
Packaging per tracker OEM field deployment specs

Industry Standards

Standards Governing Tracker Component Manufacturing

IEC 62817

Solar Tracker Systems — Design Qualification

Defines performance requirements for solar tracking systems including mechanical load testing, stow wind speed requirements, tracking accuracy, and reliability testing. Your machined drivetrain components must meet the dimensional specifications that satisfy these load cases.

UL 2703

Mounting Systems, Racking, and Clamping for PV

Covers mounting systems used with flat-plate PV modules and panels. Sheet metal brackets, formed rails, and clamp hardware must use UL-listed materials, meet grounding continuity requirements, and pass structural load testing per this standard.

ASTM A153

Hot-Dip Zinc Coating on Iron and Steel Hardware

Specifies zinc coating weight and uniformity requirements for hot-dip galvanized structural hardware. The utility-scale solar industry standard for pier caps, torque tube couplings, structural brackets, and fasteners requiring long-term sacrificial corrosion protection.

MIL-PRF-8625

Anodic Coatings for Aluminum and Aluminum Alloys

Defines requirements for Type I (chromic), Type II (sulfuric), and Type III (hard) anodic coatings on aluminum. Type III hard anodize (0.002–0.003" thickness, Rockwell C 60–70 hardness equivalent) is the standard specification for aluminum tracker components requiring abrasion and wear resistance.

Need Tracker Components Manufactured?

Upload your CAD files and get a quote for slew drive housings, torque tube couplings, bearing blocks, or mounting hardware — with production-intent materials and full dimensional inspection.

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Frequently Asked Questions

Solar Tracker Manufacturing FAQ

Technical questions from tracker OEM mechanical and manufacturing engineering teams.

What tolerances are required for solar tracker slew drive bearing seats?

Slew drive bearing bore seats and shaft mating surfaces typically require ±0.0005" (±0.013 mm) with surface finishes of Ra 0.8 µm (Ra 32 µin.) or better — critical for proper bearing preload distribution and fatigue life under repeated cyclic loading. Concentricity between the worm bore and output shaft seat should be held to within 0.001" (0.025 mm) TIR per ASME Y14.5-2018. These tolerances are achievable with 5-axis CNC machining and CMM verification available on request.

Which materials should I specify for solar tracker components exposed to coastal environments?

For coastal installations with chloride exposure, 316L stainless steel (UNS S31603) is the baseline recommendation for bearing housings and drivetrain interfaces due to its pitting resistance (PREN ≥ 24). For higher-strength applications like torque tube couplings in corrosive environments, duplex 2205 (UNS S32205, PREN ≥ 34) provides roughly double the yield strength of 316L at comparable corrosion resistance. Structural mounting hardware can use hot-dip galvanized carbon steel per ASTM A153 for cost-effective sacrificial protection, while lightweight actuator brackets often use aluminum 6061-T6 with Type III hard anodize per MIL-PRF-8625.

What surface treatments provide long-term outdoor protection for tracker aluminum parts?

For aluminum tracker components, the industry-standard approach is Type III hard anodize per MIL-PRF-8625 (0.002–0.003" oxide layer, Rockwell C 60–70 equivalent hardness) for abrasion resistance, often combined with TGIC polyester powder coat (2–5 mil DFT) for UV resistance. For extreme desert environments with sand abrasion and high UV, the anodize + powder coat combination is strongly recommended. For steel components, hot-dip galvanizing per ASTM A153 provides 50–100 µm sacrificial zinc coating — the utility-scale solar industry standard. Stainless steel parts benefit from citric acid passivation per ASTM A967. Actual coating life depends on site conditions and exposure severity.

How do I design sheet metal mounting brackets for galvanize-friendly manufacturing?

Design for hot-dip galvanizing requires specific considerations: minimum inside bend radius of 2× material thickness to prevent zinc cracking at bends, vent and drain holes (typically ≥ 10 mm diameter) in closed sections to allow zinc flow and prevent ash entrapment, hole-to-bend spacing of at least 3× material thickness plus bend radius to prevent distortion during forming, and uniform wall thickness to minimize differential thermal expansion in the zinc bath. Use ASTM A385 as your design reference. Formed tolerances for galvanized brackets are typically ±0.010" (±0.25 mm) — tighter than this is difficult to guarantee after the hot-dip process.

What is the prototype-to-production workflow for tracker OEM hardware?

The typical tracker hardware development cycle follows three gates: (1) 3D-printed fit-check models (typically 1–3 days) using nylon PA12 or ABS for validating connector routing, sensor housing geometry, and field assembly ergonomics; (2) CNC-machined functional prototypes (typically 10–15 days) in production-intent materials for field testing, load validation, and IEC 62817 certification testing; (3) production runs of 100–10,000+ pieces with full material traceability, dimensional inspection reports, and ASTM/ISO certifications. This gated approach lets you validate form, fit, and function before committing capital — critical for tracker OEMs managing IEC 62817 certification timelines and UL 2703 compliance.

What CNC machining considerations are specific to tracker drivetrain interfaces?

Tracker drivetrain interfaces demand specific GD&T callouts beyond basic linear tolerances. For worm gear housings: concentricity between the worm bore and output shaft seat within 0.001" (0.025 mm) TIR, perpendicularity of mounting faces to shaft centerlines within 0.0005" per inch, and surface finish of Ra ≤ 0.8 µm (Ra 32 µin.) on bearing seats for proper preload. For torque tube couplings: bore-to-OD concentricity within 0.001" TIR, keyway parallelism to bore axis within 0.001" over the keyway length. We recommend 5-axis machining for multi-feature drivetrain parts to maintain datum relationships in a single setup, eliminating fixture-induced error stacking.

Which industry standards apply to manufactured solar tracker components?

Four primary standards govern tracker component manufacturing: IEC 62817 defines performance requirements for solar tracking systems including mechanical load testing and stow wind speed requirements — your machined drivetrain components must meet the dimensional specs that satisfy these load cases. UL 2703 covers mounting systems, racking, and clamping used in PV installations — your sheet metal brackets and formed mounting hardware must use UL-listed materials and meet grounding continuity requirements. ASTM A153 specifies hot-dip zinc coating requirements for structural steel hardware — the standard finish for utility-scale mounting components. MIL-PRF-8625 defines anodic coating requirements for aluminum parts — Type III hard anodize is the go-to for tracker aluminum components requiring abrasion resistance. Note: compliance with these standards is the responsibility of the system integrator; we manufacture components to support your certification requirements.

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Tolerances as tight as ±0.0005" with 5-axis capability