U.S. DOE and Kodak Advance Perovskite Solar Cell Manufacturing with High-Speed Roll-to-Roll Printing, Targeting 4GW Annual Production and Enhanced Durability

U.S. Department of Energy (DOE) USA

Overview

The U.S. Department of Energy (DOE) has highlighted efforts by Energy Materials Corporation (EMC) and Jinsong Huang’s team to manufacture perovskite solar cells using Kodak’s high-speed roll-to-roll printers. This groundbreaking technology has increased the coating speed of liquid perovskite solutions by fivefold, aiming for an annual production capacity of 4 gigawatts (GW). The project addresses challenges in low-cost, high-speed solar cell manufacturing, with a particular focus on improving product durability.

In Depth

Key Findings

The U.S. Department of Energy (DOE) has showcased a groundbreaking approach to manufacturing perovskite solar cells, led by Energy Materials Corporation (EMC) and Jinsong Huang’s team from the University of North Carolina at Chapel Hill. This initiative utilizes Kodak’s high-speed roll-to-roll printers, renowned for their use in photographic film production. A major achievement of this project is a fivefold increase in the coating speed of liquid perovskite solutions. This advancement brings the production of perovskite solar cells at a scale capable of generating 4 gigawatts (GW) of electricity annually closer to reality, promising dramatic reductions in manufacturing costs and significantly improved long-term product durability.

Technical Details

Roll-to-roll printing is a manufacturing technique suitable for low-cost, high-volume production, involving the continuous application of functional materials onto flexible substrates. Kodak’s printers offer exceptional precision and speed in this process, enabling uniform and efficient formation of perovskite layers. Compared to conventional batch manufacturing, the roll-to-roll process substantially reduces production time and energy consumption. The EMC and Huang team optimized ink composition, drying conditions, and post-deposition annealing processes to adapt this technology for perovskite materials. This results in homogeneous perovskite films with fewer defects over large areas, achieving high power conversion efficiency and stability. A particular focus is placed on enhancing durability in harsh environments, such as high humidity and elevated temperatures, with new encapsulation technologies and interface engineering being developed concurrently.

Background & Context

Perovskite solar cells hold immense promise as a next-generation photovoltaic technology due to their high theoretical efficiency and the availability of low-cost materials. However, a primary barrier to their commercialization has been establishing a scalable and cost-effective manufacturing method. The DOE’s strategy to leverage existing printing technologies and expertise, such as Kodak’s, to overcome this manufacturing challenge is highly logical. This approach bypasses the need for cleanroom environments and expensive equipment typically required for traditional semiconductor manufacturing, potentially accelerating the widespread adoption of photovoltaic technology. This initiative is positioned as a critical step for the U.S. to lead globally in clean energy technologies and enhance energy security.

Strategic Significance & Outlook

Further optimization and scale-up of this high-speed roll-to-roll printing technology are expected to significantly reduce the cost of perovskite solar cells and accelerate their market entry. The annual production target of 4 GW is equivalent to powering millions of homes and holds significant implications for expanding solar energy’s share in the global energy mix. In the future, flexible perovskite modules are anticipated to be deployed in diverse applications, including Building-Integrated Photovoltaics (BIPV), portable electronics, and electric vehicles. This technology has the potential to boost clean energy utilization and make substantial contributions to achieving a sustainable society.