Thermo-mechanical loads induce stresses in photovoltaic (PV) modules, leading to crack formation. In this context, the understanding of module's thermo-mechanical behavior is important. To investigate the thermo-mechanical behavior of smart wire connected technology (SWCT) and busbarPV modules throughout their entire life, the present study is conducted that probes the stress distribution and deformation during production, transportation, and subsequent mechanical and thermal loading stages in a consecutive step-by-step manner using finite element modellingapproach. Pre-stresses and non-linearitiesare considered in simulation models. Stresses and displacements experienced by different parts/layers are examined, and crack sensitive regions are identified. In addition, the SWCTand busbar-modules are compared, and it is found that SWCTinterconnection is relatively a less stress inducing process and less susceptible to thermal and dynamic affects. During production stage, stresses of 39.3 MPaand 40.4 MPaare generated in SWCTcells and copper wires respectively; while, stresses of 60 MPaand 87 MPaare generated in busbarcells and busbarrespectively. Similarly, lower stresses are induced in SWCTPV modules during subsequent stages. The comparison results show advantages of SWCTmodule in terms of mechanical stability which can lead to improve the performance and reliability of PV modules. (C) 2018 Elsevier Ltd. All rights reserved.