Accelerating the translation of open-air spray-plasma manufactured large-area perovskite solar modules

Current photovoltaic (PV) technologies have achieved a record low Levelized Cost of Energy (LCOE) of approximately $0.03/kWh. However, the PV industry’s reliance on expensive low-throughput manufacturing processes limits cost-effective applications and equitable energy access. Perovskite solar cells present a promising alternative for broadly distributed PV – they employ low-cost materials but still face challenges in low fabrication throughput and stability.

This project will explore the use of Rapid Spray Plasma Processing (RSPP) toward achieving affordable and equitable PV using the fastest known perovskite fabrication rates of 12 meters per minute. This method exploits high-throughput open-air processing, eliminating the need for costly vacuum systems and inert gas environments. RSPP delivers low-cost perovskite PV modules projected to match current LCOEs with only 10-year module lifetimes, significantly lowering the barrier to scale. The team plans to assess process feasibility and to engage with industry stakeholders on pathways to integrate and scale this potential manufacturing innovation.