Auto BOM Generation

Auto BOM Generation refers to the automated creation of a Bill of Materials (BOM) for a solar PV system using design software. Instead of manually listing every component—modules, inverters, racking parts, wiring, BOS items, connectors, and hardware—the software analyzes the system layout and instantly produces a complete, accurate BOM based on the design’s specifications.

This automation dramatically speeds up engineering workflows, reduces human errors, and helps EPCs, installers, and sales teams generate precise proposals, permit-ready documentation, and procurement lists. Auto BOM Generation is especially valuable when integrated into advanced platforms like Solar Designing, where layout, stringing, electrical design, and shading analysis align seamlessly to produce accurate material requirements.

Key Takeaways

Auto BOM Generation instantly creates accurate material lists based on the solar design.
Eliminates manual errors and accelerates engineering workflows.
Essential for proposals, permitting, procurement, and installation planning.
Works best within integrated platforms like SurgePV that unify layout, electrical design, and modeling.
Reduces cost overruns, missed components, and design-install mismatches.

What Is Auto BOM Generation?

Auto BOM Generation is the process where solar design software automatically compiles a complete Bill of Materials based on:

Array layout
Stringing configuration
Inverter and equipment selections
Mounting structure details
Electrical BOS requirements
AHJ compliance rules
Roof or ground-mount geometry

The tool evaluates the full system model and outputs:

Module count
Inverter quantity and models
Optimizers, microinverters, MLPE
Wire types and lengths
Racking components
Mounting accessories
Conduits, breakers, fuses
Junction boxes and disconnects
Labels & safety signage

Auto BOM Generation ensures BOMs are always aligned with the exact design, removing discrepancies that often occur when engineering, sales, and installation teams work from separate documents.

How Auto BOM Generation Works

1. The designer completes the system layout

Software reads panel placement, orientation, tilt, and roof or site boundaries.

2. The stringing and electrical design are applied

Series/parallel configurations and inverter sizing feed into material calculations.

See Stringing & Electrical Design.

3. Equipment is selected

Modules, inverters, MLPE, and racking systems are chosen from the component library.

4. Software compiles materials

Rules-based engines calculate:

Exact module quantity
Racking rails/clamps
Conduit/combiner needs
AC/DC wiring
BOS devices
Safety equipment

5. Validation & QA checks

The BOM is cross-checked against NEC, AHJ, and manufacturer specifications.

6. Export-ready formats are produced

The tool generates outputs for:

Procurement teams
Installers
Permitting
Sales proposals
Project managers

This aligns perfectly with workflows inside SurgePV’s Solar Designing platform.

Types / Variants of Auto BOM Generation

1. Layout-Based Auto BOM

Driven by module count, row spacing, and racking geometry.

2. Electrical Auto BOM

Generated from inverter sizing, conductor calculations, and BOS design.

3. MLPE-Driven Auto BOM

Applies automatically calculated quantities of optimizers or microinverters.

4. AHJ-Compliant Auto BOM

Includes labeling, disconnects, and safety equipment required by local jurisdictions.

See AHJ Compliance.

5. Utility-Scale BOM Automation

Includes tracker hardware, medium-voltage transformers, and SCADA components.

How It's Measured

Auto BOM Generation does not use a traditional numerical measurement, but effectiveness is evaluated by:

1. Accuracy

How closely the automated BOM matches the final installed materials.

2. BOM Completeness

Ensuring no missing or unnecessary components.

3. Consistency

Repeatable outputs across designers, teams, and projects.

4. Time Savings

Reduction in engineering hours per project.

5. Cost Predictability

Enables reliable procurement and proposal pricing.

Typical Values / Ranges

Utility-scale projects may involve thousands of individual parts, making automation essential.

Practical Guidance for Solar Designers, Installers & EPCs

1. Complete layout and stringing before generating the BOM

Accurate design → accurate BOM.

2. Use up-to-date component libraries

Ensure modules, inverters, and racking components reflect current inventory.

3. Validate AHJ-specific safety materials

Fire labels, disconnects, rapid shutdown devices—see AHJ Compliance.

4. Combine Auto BOM with shading and performance modeling

Tools like Shadow Analysis help ensure the system performs as expected.

5. Use SurgePV’s workflow automation

SurgePV integrates layout, stringing, modeling, and Auto BOM seamlessly:

Solar Designing

✔ 6. Export BOMs in multiple formats

Ideal for procurement, installation teams, and proposal generation.

Real-World Examples

1. Residential Rooftop Project

A designer completes an 8 kW layout. Auto BOM instantly lists:

18 panels
1 inverter
Racking pieces
Wiring
Safety labels
Hardware

Procurement receives a clean export with zero manual input.

2. Commercial Flat-Roof Installation

A 320 kW array is designed using a ballasted racking system.

Auto BOM calculates:

Ballast blocks
Tilt brackets
Rail lengths
AC/DC BOS

This saves 10+ engineering hours.

3. Utility-Scale PV Farm

A 50 MW tracker-based project requires thousands of components.

Auto BOM compiles:

Tracker torque tubes
Mounting hardware
Combiner boxes
MV transformers
SCADA materials

Ensures procurement accuracy across large volumes.