This paper presents results of a theoretical study carried out to investigate the effect of flow maldistribution, caused by the manufacturing imperfections and tolerances, on the thermal efficiency of a solar air heater array with subcollectors in parallel. The air mass flow rate, ambient temperature, solar insolation and wind heat transfer coefficient have been systematically varied to study the effect under a wide range of these parameters. The collector length, duct height, and plate emissivity were also changed to study their effect. It has been found that the maximum reduction in thermal efficiency due to flow maldistribution is less than about 3% for an array with a commercial grade finish of duct surfaces and +/- 10% manufacturing tolerance for the duct height. (C) 2006 Elsevier Ltd. All rights reserved.