Tiny Grooves Unlock New Potential in Solar Cell Manufacturing

Tiny Grooves Unlock New Potential in Solar Cell Manufacturing

by Sophie Jenkins

London, UK (SPX) Feb 20, 2025

A breakthrough in solar energy technology has been achieved by researchers at the University of Sheffield, in collaboration with UK-based company Power Roll Ltd. Their study, published in *ACS Applied Energy Materials*, introduces an innovative method of manufacturing flexible solar cells without the use of rare earth metals, offering a more affordable and efficient approach to solar power.

The newly developed solar cells employ a perovskite semiconductor and are manufactured using an embossing technique that etches microscopic grooves into plastic film. These grooves are then filled with the perovskite material, resulting in lightweight and flexible solar films that can be applied to unconventional surfaces, such as rooftops that cannot support conventional solar panels. With their reduced cost and adaptability, these cells have the potential to accelerate solar energy deployment, particularly in developing regions where access to traditional solar infrastructure is limited.

The key innovation in this technology is its back-contact solar cell format, which differs from traditional layered solar cells. By placing all electrical contacts on the back of the cell, this design simplifies manufacturing and enhances efficiency. The research team utilized a Hard X-ray nanoprobe microscope at Diamond Light Source in Oxfordshire to analyze the structure and composition of the solar cells in unprecedented detail. This analysis helped identify voids, defects, and crystal boundaries within the semiconductor material, marking the first time such imaging techniques have been applied to this type of solar technology.

Unlike conventional solar cells that rely on costly and scarce materials such as indium, this new approach uses widely available components, making it an economically viable and sustainable alternative. Professor David Lidzey, co-author of the study and a researcher at the University of Sheffield’s School of Mathematical and Physical Sciences, highlighted the significance of this advancement.

“A key advantage of these flexible films is that the panel can be stuck onto any surface. In the UK, you currently have to think twice about adding thick solar panels onto relatively fragile roofs of warehouses that are not really designed to be load-bearing. With this lightweight solar technology, you could essentially stick it anywhere. This could be a gamechanger for solar energy in low and middle-income countries.”

He further emphasized the strategic importance of solar energy research at the university, noting their decade-long partnership with Power Roll Ltd. “We’ve partnered with Power Roll for over 10 years, combining our expertise in materials science and advanced imaging techniques with their focus on manufacturing, and this collaboration has been very successful, resulting in this exciting new product.”

The University of Sheffield is globally recognized for its leadership in sustainability and advanced manufacturing. Its collaboration with Power Roll reflects a shared commitment to advancing renewable energy solutions and fostering innovative technologies that address pressing global energy challenges.

Dr. Nathan Hill, lead author of the study and research scientist at Power Roll, underscored the impact of this partnership: “This partnership demonstrates the potential of combining cutting-edge research with industrial innovation to deliver transformative solutions in renewable energy. We are advancing technology that could play a significant role in achieving global net-zero targets, and by combining our collective research and academic capabilities we are able to further prove out the science sitting behind Power Roll’s technology.”

He also noted prior collaborative efforts with the University’s Department of Physics and Astronomy to enhance solar cell designs, leading to reductions in manufacturing costs and improvements in solar efficiency.

With perovskite-based solar technology still in its early stages, ongoing research and academic exploration are crucial to refining product development and deepening scientific understanding. The next phase of this research will focus on advancing X-ray microscopy techniques for further material characterization. New experiments scheduled for the summer at Diamond Light Source aim to investigate key aspects of device operation, particularly stability.

Dr. Jessica Walker, I14 beamline scientist at Diamond Light Source Ltd., emphasized the importance of these upcoming studies: “The techniques and resolution offered by I14 are ideally suited to help answer scientific questions that remain around perovskite-based solar cell materials. It is exciting to see how our capabilities have contributed to both academic and industrial research and culminated in such a promising development for the field of energy materials, as well as a direct and tangible application with high potential for impact.”

Research Report:Back-contact Perovskite Solar Cell Modules Fabricated via Roll-to-Roll Slot-die Coating: Scale-up Towards Manufacture