Support insert for thin film photovoltaic devices and their methods of manufacture

A photovoltaic device, comprising:

• a transparent substrate;
• a plurality of thin film layers on the transparent substrate, wherein the plurality of thin film layers define a plurality of photovoltaic cells connected in series to each other;
• a first lead connected to one of the photovoltaic cells;
• an encapsulation substrate on the plurality of thin film layers, wherein the encapsulation substrate defines a back surface and a connection aperture through which the first lead extends, the connection aperture having a perimeter defined by an aperture wall of the encapsulation substrate;
• and,
• a support insert defining a plug portion and a flange, wherein the plug portion is positioned within the connection aperture and the flange extends over the back surface of the encapsulation substrate, wherein the support insert is configured to mechanically support the transparent substrate in an area opposite to the connection aperture, and wherein the support insert is configured such that the first lead is able to extend through the connection aperture while the support insert is in place within the connection aperture.