Engineering

Morningstar is renowned for delivering the industry’s best overall customer value. Our controllers & inverters have set new standards in performance, innovative features, quality & reliability. Our products are manufactured in a fully automated world-class ISO 9001 facility. Our Quality Control includes 100% functional testing on every product, using the latest computerized test equipment and processes.

As part of our commitment to designing and building the industry’s best-in-class products, we have consistently invested in strengthening our R&D capabilities and staffing. Furthermore, we hold several advanced technology & manufacturing process patents that set our products apart from the competition in quality, reliability, performance and above industry average operating life.

With over 4 million products sold in over 100 countries since 1993—functioning in some of the most extreme environments & mission-critical applications in the world—Morningstar Corporation is truly “the leading supplier of solar controllers and inverters.” Morningstar’s stable management along with the lowest employee turnover rate has led to our success. Morningstar’s main advantage is our employee ownership. Our own reputations ship with each product we make. We continually strive to keep our quality and reliability at an industry-record high. Quality and value are not just catch-phrases, they actually mean something at Morningstar. We invest 9% of our annual revenues in R&D capabilities.
This, plus investing in our people, assures that we continually earn our leadership reputation for quality, technological innovation, and value. Morningstar’s technical edge is maintained through an all-out commitment to:

  • Tools and facilities—we model, plan, construct and build our ideas. Our team is capable of working through mechanical & thermal designs and simulations, building advanced prototypes and designing on-site printed circuit board layouts. Our dedicated engineering center has its own advanced R&D facilities, test lab, EMI and environmental chambers,and full-thermal modeling tools including 3D CAD Software for mechanical & thermal design and product simulation. We maintain a 35kW solar system at our facility for real-world testing, research, and evaluation. A non-site machine shop houses soldering, stripping and re-flow equipment to augment our advanced in-house circuit board prototyping capabilities. We have a variety of tools and machines for prototype enclosure fabrication. Our advanced testing lab includes:
    • EMI (electromagnetic interference) Chamber –isolated from exterior sources of noise, this anechoic environment completely absorbs reflections of both sound waves and electromagnetic radiation. Allowing us to test products to meet FCC Part 15 Subpart B / ICES-003 standards.
    • Environmental Chamber –tests for various environmental parameters including, but not limited to, extreme temperatures, sudden and extreme temperature variations, moisture or relative humidity, vibrations, weathering, exposure to sunlight and salt spray.
    • Testing Center –equipped with an arrayof scopes, analyzers, and diagnostic equipment as well as on-site printed circuit board layout facilities for faster, in-house product development.
  • Intellectual Property (IP)—Innovation is not a buzzword for us, we have a quarter-century of industry “firsts”. With over 20 patents and a dozen trademarks, Morningstar leads the field in off-grid power conversion technology. Our low turnover and long-term team approach foster an environment where technical creativity thrives, resulting in an IP portfolio that’s broad and comprehensive for a company our size. Morningstar’s patents cover many areas including
    thermal engineering, mechanical design, charging control, advanced electronic topologies, and safety systems.
  • Design—we’ve pioneered smarter digital design for solar components, for faster, more agile processing on-board. This allows us to extract all the performance possible from our hardware.
    We use advanced thermal engineering to eliminate cooling fans—the weak link in competitors’ products. Finally, our internal electronics are laid out for performance and longevity instead of economics—we design for the long-term instead of a bottom line, in order to achieve the industry’s lowest hardware failure rates.
  • Quality—With our design and internal engineering excellence, we could get higher performance than our competitors while using the same “good enough” components they do. Instead, we raise the bar by using over-spec’d superior components and build them in a fully ISO 9001 factory. That’s why many of the Morningstar products built since 1993 are still in use.