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Structural Support Rails CNC Machining for Solar Panel Mounts
With Zintilon CNC Machining of Solar Mounting Rails, we provide you with exceptional and dependable structural integrity, corrosion resistance, and ease of installation for long-term residential, commercial, and utility-scale solar arrays.
Structural support rails are made from precise machining in which mounting profiles are accurately attached to points and provide load distribution for all configurations of photovoltaic modules in rooftop, ground-mount, and tracking solar installations.
- Machining for complex rail profiles and mounting interfaces
- Tight tolerances up to ±0.010 in
- Precision cutting, drilling & weather-resistant finishing
- Support for rapid prototyping and full-scale production
- ISO 9001-certified solar mounting system manufacturing
Trusted by 15,000+ businesses
Why New Energy Companies
Choose Zintilon
Fast Delivery
A professional engineering team that can respond quickly to customer needs and provide one-stop services from design to production in a short period of time to ensure fast delivery.
High Precision
We are equipped with automated equipment and sophisticated measuring tools to achieve high accuracy and consistency, ensuring that every part meets the most stringent quality standards.
ISO13485 Certified
As a ISO13485 certified precision manufacturer, our products and services have met the most stringent quality standards in the automotive industry.
From Prototyping to Mass Production
We provide CNC machining of structural support rails and associated mounting profiles to solar installers, racking system manufacturers, and photovoltaic project developers around the world.
Prototype Structural Support Rails
High-precision prototypes of mounting rails that closely match your final design can be produced. Testing includes load capacity, installation efficiency, and structural integrity prior to embarking on full-scale production.
Key Points:
Key Points:
- Rapid prototyping with high precision
- Tight tolerances (±0.010 in)
- Test design, strength, and corrosion resistance early
EVT – Engineering Validation Test
Quick and efficient support rail prototypes that streamline all structural, and environmental requirements validation to identify problems early on in the process for seamless full-scale solar mounting.
Key Points:
Key Points:
- Validate prototype functionality
- Rapid design iterations
- Ensure readiness for production
DVT – Design Validation Test
Support rails, that were designed to hold solar panels, have encumbrance designed and load capacity tested to verify, design accuracy, optimal panel support prior to mass production, and various coatings to ensure performance.
Key Points:
Key Points:
- Confirm design integrity and heat transfer
- Test multiple materials and channel configurations
- Ensure production-ready performance
PVT – Production Validation Test
Large-scale production feasibility for structural support rails is confirmed to identify potential barriers in production prior to ensuring consistent and efficient full production.
Key Points:
Key Points:
- Test large-scale production capability
- Detect and fix process issues early
- Ensure consistent part quality
Mass Production
Produce high-quality, corrosion-resistant support rails at scale with precision and speed, ensuring reliable panel mounting and on-time delivery for solar installers and renewable energy developers.
Key Points:
Key Points:
- Consistent, high-volume production
- Precision machining for outdoor durability
- Fast turnaround with strict quality control
Simplified Sourcing for
the New Energy Industry
Our precision manufacturing capabilities are widely used in the new energy industry. CNC machining, sheet metal fabrication and other technologies ensure high precision and heat resistance in the application of new energy grade materials such as titanium alloy and PEEK.
Explore Other New Energy Components
Browse our complete selection of CNC machined components for new energy applications, crafted for precision and long-term reliability. From turbine housings and mounting brackets to battery enclosures and thermal management components, we deliver solutions tailored to the evolving needs of renewable energy and clean technology industries.
Solar Panel Mount Structural Support Rails Machining Capabilities
Our advanced CNC cutting and drilling equipment, combined with experienced solar mounting machinists, deliver Structural Support Rails CNC Machining for Solar Panel Mounts. From universal mounting rails to custom profiles and adjustable tilt rails with integrated attachment points, every component is engineered for optimal load distribution, installation speed, and 25-year weather resistance.
We provide precision rail cutting, coordinate drilling, end milling, and anodizing for perfect panel alignment and corrosion protection, along with load testing and dimensional verification. Each structural support rail is machined from aluminum extrusions (6005-T5, 6063-T6), stainless steel (304, 316), or hot-dip galvanized steel, ensuring exceptional strength and corrosion resistance under decades of outdoor exposure in solar installations.
We provide precision rail cutting, coordinate drilling, end milling, and anodizing for perfect panel alignment and corrosion protection, along with load testing and dimensional verification. Each structural support rail is machined from aluminum extrusions (6005-T5, 6063-T6), stainless steel (304, 316), or hot-dip galvanized steel, ensuring exceptional strength and corrosion resistance under decades of outdoor exposure in solar installations.
Aerospace
Materials & Finishes
Materials
We provide a wide range of materials, including metals, plastics, and composites.
Finishes
We offer superior surface finishes that enhance part durability and aesthetics for applications requiring smooth or textured surfaces.
Specialist Industries
you are welcome to emphasize it in the drawings or communicate with the sales.
Materials for Structural Support Rails
Our CNC machine shop sells and modifies more materials for Structural Support Rails Machining for Solar Panel Mounts than any other shop. Weather-resistant metal alloys and a range of alloys for supports of varied weights and prototyping supports of solar mounting for rapid precision solar mounting for a 25 year outdoor guaranteed durability of solar mounting for a 25 year outdoor guaranteed durability.
High machinability and ductility. Aluminum alloys have good strength-to-weight ratio, high thermal and electrical conductivity, low density and natural corrosion resistance.
Price
$ $ $
Lead Time
< 7 days
Tolerances
Down to ±0.003 mm
Max part size
3000*2200*1100 mm
Min part size
2*2*2 mm
Stainless steel alloys have high strength, ductility, wear and corrosion resistance. They can be easily welded, machined and polished. The hardness and the cost of stainless steel is higher than that of aluminum alloy.
Price
$ $ $
Lead Time
< 7 days
Tolerances
Down to ±0.005 mm
Max part size
3000*2200*1100 mm
Min part size
2*2*2 mm
Steel is a strong, versatile, and durable alloy of iron and carbon. Steel is strong and durable. High tensile strength, corrosion resistance heat and fire resistance, easily molded and formed. Its applications range from construction materials and structural components to automotive and aerospace components.
Price
$ $ $ $ $
Lead Time
< 10 days
Tolerances
Down to ±0.001 mm (routing)
Max part size
3000*2200*1100 mm
Min part size
2*2*2 mm
Titanium is an advanced material with excellent corrosion resistance, biocompatibility, and strength-to-weight characteristics. This unique range of properties makes it an ideal choice for many of the engineering challenges faced by the medical, energy, chemical processing, and aerospace industries.
Price
$$$
Lead Time
< 10 days
Tolerances
Down to ±0.005 mm
Max part size
3000*2200*1100 mm
Min part size
2*2*2 mm
Highly resistant to seawater corrosion. The material’s mechanical properties are inferior to many other machinable metals, making it best for low-stress components produced by CNC machining.
Price
$ $ $ $ $
Lead Time
< 10 days
Tolerances
Down to ±0.005 mm
Max part size
3000*2200*1100 mm
Min part size
2*2*2 mm
Brass is mechanically stronger and lower-friction metal properties make CNC machining brass ideal for mechanical applications that also require corrosion resistance such as those encountered in the marine industry.
Price
$$$
Lead Time
< 10 days
Tolerances
Down to ±0.005mm
Max part size
3000*2200*1100 mm
Min part size
2*2*2 mm
Few metals have the electric conductivity that copper has when it comes to CNC milling materials. The material’s high corrosion resistance aids in preventing rust, and its thermal conductivity features facilitate CNC machining shaping.
Price
$$$
Lead Time
< 10 days
Tolerances
Down to ±0.005 mm
Max part size
3000*2200*1100 mm
Min part size
2*2*2 mm
Zinc is a slightly brittle metal at room temperature and has a shiny-greyish appearance when oxidation is removed.
Price
$ $ $ $ $
Lead Time
< 10 days
Tolerances
Down to ±0.005 mm
Max part size
3000*2200*1100 mm
Min part size
2*2*2 mm
Iron is an indispensable metal in the industrial sector. Iron is alloyed with a small amount of carbon – steel, which is not easily demagnetized after magnetization and is an excellent hard magnetic material, as well as an important industrial material, and is also used as the main raw material for artificial magnetism.
Price
$ $ $ $ $
Lead Time
< 10 days
Tolerances
Down to ±0.005 mm
Max part size
3000*2200*1100 mm
Min part size
2*2*2 mm
Due to the low mechanical strength of pure magnesium, magnesium alloys are mainly used. Magnesium alloy has low density but high strength and good rigidity. Good toughness and strong shock absorption. Low heat capacity, fast solidification speed, and good die-casting performance.
Price
$ $ $ $
Lead Time
< 7 days
Tolerances
Down to ±0.005 mm
Max part size
3000*2200*1100 mm
Min part size
2*2*2 mm
Let’s Build Something Great, Together
FAQs: Cooling Plates for Solar Inverter Applications
Structural support rails are aluminum or steel profiles securing photovoltaic modules to roofs, ground structures, or tracking systems while distributing wind and snow loads. Types include universal mounting rails with continuous T-slots accepting mid clamps and end clamps for modules from 30 to 72 cells, C-channel rails providing superior bending strength for spans exceeding 3 meters, top-hat rails for low-profile rooftop installations, adjustable tilt rails enabling angle optimization from 5 to 60 degrees, shared rails supporting adjacent module rows reducing material cost by 15 to 25 percent, and specialty profiles including curved rails for building-integrated photovoltaic applications, telescoping rails accommodating thermal expansion in arrays exceeding 100 meters, and heavy-duty rails for trackers supporting dynamic wind loads.
Aluminum extrusions 6005-T5 and 6063-T6 have a good strength-to-weight ratio, with 215 to 240 MPa yield strength and supporting spans of 4 meters, over 25 years of corrosion resistance, and Thermal expansion 23.6 ppm, per Kelvin which is similar to the glass, which reduces stress, roof loading is reduced by 50 to 65 percent, and used as coating aluminum is cheap compared to steel. For a 30-year service life, stainless steel 304 and 316 will have significant strength and corrosion resistance compared to stainless steel and withstand marine environments to 500 meters of saltwater. Hot-dip galvanized steel per ASTM A123 is cheap, has adequate strength for galvanized steel, and offers a 25-year corrosion barrier in mild climate zinc which will also galvanized steel. It is also rust protection in zinc will allow to reliable ground-mount utility-scale installations.
Cutting saws are used to precision cut aluminum extrusions to specified lengths. Steel profiles are cut to length with length tolerance of ±0.010 inches for alignment purposes and for end squareness of ±1 degrees. CNC coordinates drilling for mounting, grounding, and splice connector holes with position accuracy of ±0.005 inches to standardize the spacing for clamps which are usually between 1000 to 1200 millimeters apart. End milling machines slots, notches, and wire management channels. Deburring sharp edges is to prevent installer injuries and to ensure proper seating of clamps. Punching for attachment holes is typical in high volume. Both anodizing aluminum and powder coating steel are used to prevent corrosion and for aesthetics.
To achieve proper array fit and module alignment, rails are ±0.010 inches in length. Mounting holes for clamps are ±0.005 inches which ensures 40 to 50 millimeter spacing accuracy. End squareness is ±1 degree which is necessary for flush rail-to-rail connections. Straightness control of 0.005 inches is achieved per meter of length to prevent module twist. Profile dimensions are ±0.015 inches to maintain clamp and T-slot interface specifications.
Yes, we provide rapid prototyping to verify fit and test assembly, with same-day CAD-to-part capability available for critical projects. For custom automation cells and research platforms, we perform low-volume production of 20 to 500 brackets. For standardized robot models, we perform high-volume production of thousands to tens of thousands of brackets annually, incorporating complete dimensional inspection, flatness verification, and material certifications.
All components are manufactured under an ISO 9001 quality management system, including complete material traceability. Each component’s dimensions are verified against design specifications and tested to structural requirements, which include mount testing to TÜV certified solar mounting standards, UL 2703 for rack mounting systems, and local building codes that include IBC and ASCE 7. This also includes structural integrity for module loads and environmental forces. We provide 25 to 30 years of corrosion resistance that matches the solar panel warranties, ensuring electrical continuity with a grounding path resistance of less than 5 milliohms.
We provide comprehensive finishing solutions tailored to aerospace requirements:
Anodizing (Type II and Type III)
Passivation for corrosion resistance
Precision polishing for aerodynamic surfaces
Custom protective coatings and thermal barriers
Anodizing (Type II and Type III)
Passivation for corrosion resistance
Precision polishing for aerodynamic surfaces
Custom protective coatings and thermal barriers
Standard cut-to-length aluminum rails with coordinate drilling require 8–14 business days including cutting, machining, and anodizing, while custom profile development with specialized extrusion dies needs 10–14 weeks for initial tooling. Prototype rail sections for structural testing can be completed in 5–8 days enabling rapid mounting system validation.
Certainly, we specialize in creating custom support rails to meet unique structural requirements. They can be horizontally elongated over 5m for use on carport and canopy structures where rams are required to have a bending moment of over 10 Kn-m. We also have low profile rails that are 40mm high on flat commercial roofs for wind loaded ballasted systems that are stable. We manufacture custom curved rails for building contour and BIPV integration and systems with radius of 5m. Other unique designs we have include acoustically dampened rails, seismic rated rails, and pre-assembled rail mounting systems.
Railing precision machining entails the maintenance of accurate intervals of 10 +/- 0.010 in along the entire length of the array so that the set modules configured in the design can maintain the electrical string configuration. This arrangement promotes efficient routing of cables in the array. Providing positions of the mounting holes 10 +/- 0.005 in also promotes efficiency in the mid clamps as well as the end clamps and in the spacing patterns between clamps which is set between 1000 and 1200 millimeters. This ensures that the modules are held down with at least 4 support points which lessens wind uplift while also keeping the array flat within 5 mm of each other. Ensuring straightness of the rails to 0.005 in per meter also assists and straightening the modules which can cause uneven twist and pressure. This can lead to broken laminates as well as air gaps of the modules which can lower the output of the module to 5 % 0. Squareness of the end rails to 1 degree assists in the creation of flush joint connections and helps in the equal distribution of load in splice joints covering more than 10 m of continuous rails. Good quality sections as well as tubo section modulus are directly proportional to the span length and bending strength. This bending strength is used to resist the load of wind and snow and in compliance with ASCE 7 snow load of 5400 Pascals and wind load of 1200 to 2400 Pascals. The protective paint ensures the stability of the structure and maintains the ground of the electric discharge. This is due to the impact of UV rays and other extreme environmental conditions such as temperature ranging between -40 and 85 degrees centrigrade along with other humid conditions.
When done correctly, manufacturing allows for reliable panel mounting for solar installations, with structures having the capacity to meet local building codes; installations become more efficient, reducing labor time by 20 to 30 percent due to standardized hole patterns; and the service life for residential rooftop arrays, commercial ground-mount systems, and utility-scale solar farms from 1 megawatt to 100+ megawatts exceeds 25 years.
When done correctly, manufacturing allows for reliable panel mounting for solar installations, with structures having the capacity to meet local building codes; installations become more efficient, reducing labor time by 20 to 30 percent due to standardized hole patterns; and the service life for residential rooftop arrays, commercial ground-mount systems, and utility-scale solar farms from 1 megawatt to 100+ megawatts exceeds 25 years.
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