How Translucent Panel Daylighting Systems are Made


  • Fiberglass Reinforced Polymer (FRP) face sheet
  • Internal Aluminum Grid Core (Thermally broken or non-thermally broken)
  • Adhesives (Bonding of Face Sheet to Grid Core)
  • Aluminum Framing (Thermally Broken or Non-thermally Broken)
  • Gaskets and Fasteners
  • Options – Insulation / High Impact Sheet / Lifting Tabs


Panels are made by “sandwiching” an aluminum grid core between two FRP face sheets. Insulation can also be added for enhanced thermal performance, and thermal breaks are also available.

The process begins with processing the aluminum that will be used for both the framing system and panel grid. Aluminum extrusions are cut to size and any holes or other alterations are cut or drilled before materials are sent to our finishing partner for Kynar® paint or anodize finishing, depending upon the color and method specified. Once finishing is complete, all gasketing and/or sealing tapes are applied (depending on system configuration).

One of the main components of a translucent panel system is the fiberglass sheet itself. FRP face sheets are made by combining a mixture of resins and catalysts with glass rovings, as well as a glass veil that provides additional weathering benefits and adds to the system’s long-term performance. The sheet is cured with heat and is then ready to be used to make our panel systems.

Once the internal aluminum grid core is assembled, translucent fiberglass face sheet is then cut to size and attached using a high-performance adhesive. If the system calls for insulation, that material is added at this time as well. Once the sheet and adhesive is fully bonded, the panel is complete and is then ready to be crated and shipped with other necessary components needed for installation. In select configurations, Major also offers pre-assembled, partially-assembled and unitized system options, allowing us to build systems in the controlled environment of our factory, which in turn saves time on-site and can cut down on installation errors.

Whether the system is pre-assembled or shipped in parts to be assembled on-site, our team carefully packs and crates all materials, labeling them clearly so that they can be placed in the proper location on-site, and prepares them for shipping. Major prides itself on taking the extra time and care to securely package our systems, reducing the chance of shipping damage. If damage does occur during the shipping process, Major will also handle any freight claims and paperwork.

From initial quote to manufacturing to installtion and beyond, Major will work with to ensure the daylighting system you receive exceeds your expectations.