A Fresh Wave of Thin Film Solar Factories Delivers the Final Blow to Coal's Dominance
Imagine pouring millions of taxpayer dollars into keeping ancient coal plants alive, only to watch them get completely overshadowed by cutting-edge solar and storage solutions. But here's where it gets controversial – is this really the end of the fossil fuel era, or just a temporary setback?
To support CleanTechnica's ongoing efforts, consider subscribing via Substack at https://cleantechnica.substack.com/subscribe or contributing through Stripe at https://cleantechnica.fundjournalism.org/contribute/.
Under the brand-new "American Energy Dominance" initiative, American taxpayers are being asked to fork over substantial funds to maintain and operate obsolete coal-fired power plants. Unfortunately, those investments might end up as wasted resources. The unbeatable pairing of solar power with advanced energy storage is already leading the charge in adding new capacity to the electrical grid, and now, the U.S.-based startup First Solar is stepping forward with ambitious plans to boost local production of its advanced thin film solar technology.
Thin Film Solar and the Push for Domestic Manufacturing
Let's break down what thin film solar really means – it's exactly as straightforward as the name suggests. Unlike traditional solar cells made from bulky chunks of silicon, thin film variants use materials that can be blended into a liquid solution and applied via spraying or printing onto any surface. This innovative approach unlocks possibilities for affordable, roll-to-roll manufacturing processes, which ultimately drive down the costs of solar energy overall. (For a deeper dive into thin film technology, check out our extensive background articles here: https://cleantechnica.com/?s=thin+film+solar.)
First Solar traces its origins back to the 1990s, starting as a thin film solar pioneer called Solar Cells, Inc., specializing in cadmium telluride (CdTe) formulations – a type of semiconductor that's efficient and cost-effective. After a takeover and renaming in 1999, the company has been producing thin film solar cells under the First Solar name since 2002. Today, it proudly claims to be the only major solar manufacturer globally with its headquarters right here in the U.S. As domestic orders for its thin film tech surge – including its deployment in the largest solar farm ever in the eastern U.S. (https://cleantechnica.com/2024/08/20/thin-film-solar-deployed-in-biggest-ever-solar-farm-in-the-us-east/) – the key missing piece has been a fully American-made manufacturing base.
In recent years, First Solar has made significant strides toward that goal, with strong backing from state governments (https://cleantechnica.com/2024/09/30/new-thin-film-solar-factory-transforms-red-state-into-green-warrior/), even in traditionally conservative "red states" where leaders have prioritized economic growth and long-term job opportunities over political rhetoric. For instance, in September 2024, Alabama state and local leaders celebrated the launch of a new First Solar plant in Lawrence County.
"First Solar stands out as a top-tier manufacturer (https://governor.alabama.gov/newsroom/2022/11/governor-ivey-announces-first-solar-to-open-1-1-billion-alabama-facility-creating-over-700-clean-energy-manufacturing-jobs-in-lawrence-county/), and its solar modules are set to become vital for America's energy self-reliance," remarked Alabama Governor Kay Ivey, who endorsed the company's expansion into South Carolina back in November 2022.
The Law of Unintended Consequences in Federal Policy
However, this year's sudden changes in national energy strategy have thrown some hurdles at the growing domestic solar sector. Key among them, Congress reduced solar tax incentives with the "One Big Beautiful Bill Act" passed in July. Plus, upcoming rules limiting reliance on foreign supply chains for local production will take effect next year.
And this is the part most people miss – despite these challenges, the appetite for solar power isn't fading away. It's a well-known fact, but one worth emphasizing: solar combined with energy storage (https://cleantechnica.com/2025/11/13/us-president-caught-napping-by-us-solar-industry/) remains the fastest and most economical way to expand the nation's power grid. A recent Deloitte report highlights that renewables made up over 90% of new capacity added in the first half of this year, with solar and storage accounting for more than 80% of that total.
Given this context, it's hardly surprising that First Solar is planning another U.S. plant (https://cleantechnica.substack.com/p/first-solar-expands-cdte-solar-cell-manufacturing-footprint-in-us). Set in Gaffney, Cherokee County, South Carolina, this new facility will assemble thin film solar cells from existing First Solar factories into complete solar modules, aligning perfectly with the evolving domestic manufacturing landscape.
News of the plant first surfaced in industry publications two weeks ago. On November 14, the company officially unveiled its intentions, explaining the factors behind its anticipated success.
"This South Carolina site – designed to bolster American energy leadership and cost-effective goals – was spurred by the demand for homegrown energy solutions sparked by the One Big Beautiful Bill Act, enacted by President Donald J. Trump in July 2025," First Solar stated, acknowledging the policy's role.
"The plant is projected to boost First Solar's ability to create U.S.-made solar tech compliant with upcoming Foreign Entities of Concern (FEOC) guidelines by 3.7 gigawatts (GW), hitting 17.7 GW in annual capacity by 2027," they added, referencing the new curbs on international supply chains.
Thin Film Solar: A Job Creator in Action
South Carolina Governor Henry McMaster echoed this enthusiasm, viewing the project as a catalyst for national energy production.
"First Solar's commitment will generate 600 fresh positions in Cherokee County, significantly bolstering the regional economy and promoting America's energy autonomy," McMaster noted in an official release. "Their growing footprint here will offer even more prospects for dedicated South Carolinians."
And he's right – in a time of rising inflation, trade barriers, and the job displacements caused by AI, securing quality employment is tougher than ever. First Solar anticipates the new plant will be operational by the latter half of next year, providing much-needed relief for 600 hopeful workers in South Carolina.
So, What's the Real Deal with Coal's Fate?
First Solar emphasizes that this new addition will integrate with its existing five plants in Ohio, Alabama, and Louisiana, plus research and development hubs in California and Ohio. "By 2027, we foresee supporting more than 30,000 direct, indirect, and induced positions nationwide, contributing over $3 billion to labor earnings."
On the direct employment front, First Solar aims for over 5,500 employees by year's end. And remember, this is just one company in the solar space. Others are making waves too – keep an eye on Texas, which is positioning itself as a major hub for solar production in America (https://cleantechnica.com/2025/08/16/texas-sends-yet-another-solar-manufacturing-love-letter-to-the-us/).
For comparison, the entire U.S. coal mining industry (https://fred.stlouisfed.org/series/CES1021210001) supported roughly 41,000 jobs as of August this year. It's also important to recognize that the shift away from coal jobs is a modern trend. Employment in coal had been declining throughout the 20th century due to mechanization, peaking at 178,000 in 1985 and falling to 90,000 by 2011 – much of this driven by the natural gas boom in the early 2000s, when renewable costs were still high.
Now, with solar, wind, and storage becoming increasingly affordable, policymakers favoring coal face an uphill battle. And the future looks even tougher. Alongside thin film solar, emerging energy storage technologies (https://cleantechnica.com/2025/11/15/coal-killing-sodium-ion-energy-storage-is-coming-to-kill-your-coal-power-plants/) are hitting the market, followed closely by next-gen solar materials like tandem perovskite cells (https://cleantechnica.com/2025/11/12/you-snooze-you-lose-us-president-fails-to-stop-tandem-perovskite-solar-cells-from-happening/).
Plus, the sun will continue to shine brightly, and innovators will keep pushing boundaries, regardless of who's in the Oval Office after the peaceful transition on January 20, 2029.
Photo: First Solar, a pioneering thin film solar firm, is gearing up for a surge in demand for American-made solar modules (https://www.firstsolar.com/-/media/First-Solar/Page-Headers/Header_Overview.jpg) (cropped, courtesy of First Solar).
Do you agree that solar is sealing coal's fate, or do you think government subsidies for coal could turn the tide? Is this a controversial victory for renewables, or a necessary shift? Share your thoughts in the comments – we'd love to hear your take!
Subscribe to CleanTechnica's Weekly Substack for Zach and Scott's detailed insights and weekly highlights (https://cleantechnica.substack.com/subscribe), sign up for our daily newsletter (https://mailchi.mp/cleantechnica/daily-newsletter), and follow us on Google News (https://news.google.com/publications/CAAqLQgKIidDQklTRndnTWFoTUtFV05zWldGdWRHVmphRzVwWTJFdVkyOXRLQUFQAQ)!
Advertisement
Got a tip for CleanTechnica? Interested in advertising or suggesting a guest for our CleanTech Talk podcast? Reach out here (https://cleantechnica.com/contact/).
Sign up for our daily newsletter delivering 15 fresh cleantech stories each day (https://mailchi.mp/cleantechnica/daily-newsletter). Or opt for our weekly roundup of the biggest stories (https://mailchi.mp/cleantechnica/weekly-newsletter) if daily updates are too much.
CleanTechnica uses affiliate links. Review our policy here (https://cleantechnica.com/cleantechnica-editorial-ethics/).
CleanTechnica's Comment Policy (https://cleantechnica.com/cleantechnica-comment-policy/)
