Using renewable energy sources for onsite cogeneration from structural building elements is a relatively new concept and is gaining considerable interest. In this study the design, development, manufacturing and testing of a novel building integrated photovoltaic/thermal (BIPVT) solar energy cogeneration system is discussed. Adhesives (ADH), resistance seam welding (RSW) and autoclaving (ATC) were identified as the most appropriate for fabricating BIPVT roofing panels. Of these manufacturing methods ADH was found to be most suitable for low volume production systems due to its low capital cost. A prototype panel, fabricated using ADH methods, exhibited good thermal performance. It was also shown that BIPVT performance could be theoretically predicted using a onedimensional heat transfer model and showed excellent agreement with experimental data. The model was used to suggest further design improvements. Finally, a transient simulation of the BIPVT was performed in TRNSYS and is used to illustrate the benefits of the system.