Solar Thermal Energy Costs Cut by 40% Thanks to Lightweight Plastic Mirrors

By: | June 24th, 2025

solar farm using mirrors

Photo by Val Toch on Unsplash

Seeking sustainable energy solutions has led researchers and scientists to study innovative approaches to harnessing solar power. 

Among these, solar thermal energy stands out for its potential to directly address the heating needs of agriculture and industry with zero emissions. Currently, a group of researchers at the University of South Australia (UniSA) is developing a method to lower the cost of producing solar thermal energy by potentially as much as 40%. This innovative approach is to use lightweight plastic mirrors, which were originally designed as shatterproof rear-view mirrors for cars.

Although solar thermal energy systems and conventional solar energy (photovoltaic) panels both harvest sunlight, they work in different ways. 

While conventional photovoltaic solar panels convert sunlight into electricity, solar thermal energy captures the sun’s heat. Solar thermal energy systems employ reflectors to concentrate sunlight onto a receiver, converting solar radiation to heat energy. This heat can be used for various applications, such as heating buildings and water.

In addition, it also can be used to power agriculture and industrial facilities that require temperatures between 212 – 754 °F (100 – 400 °C). Therefore, it can address issues in numerous sectors, including food production, crop drying, soil sterilization, wastewater treatment, chemical manufacturing, paper production, water desalination, and textile dyeing.

The UniSA team has developed plastic mirrors that are shatterproof, flat-packable, and 50% lighter than their glass counterparts and are easier to design and assemble into rear-view wings for new vehicles. These mirrors use a commonly available plastic material with special reflective coatings.

UniSA’s pilot project involves constructing two models, each composed of 16 coated mirror panels featuring a multilayer aluminum-silica reflective coating. These setups will be tested at Vineyard of the Future at Charles Sturt University, a location dedicated to innovation in wine production processes.

Professor Colin Hall, the inventor of the plastic mirror coating technology, emphasizes the relevance of this technology in the context of rising fossil fuel prices and the increasing pressure on industries to decarbonize. 

In addition, he also highlights the suitability of concentrated solar thermal (CST) solutions for Australia’s climate, offering a pathway to zero-emissions process heat.

Dr. Marta Llusca Jane, the UniSA project lead, underscores the importance of such innovations in achieving sustainable energy solutions.

Ashton Henning

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