Roll-to-roll (R2R) manufacturing is central to the industrialization of perovskite photovoltaics, yet module-level integration remains one of the least resolved challenges. While continuous coating of perovskite device stacks has advanced rapidly, scalable interconnection strategies compatible with uninterrupted web processing are still largely challenging. Although effective at laboratory and pilot scales, laser-based patterning introduces fundamental incompatibilities with continuous R2R manufacturing, including thermal damage, debris generation, alignment sensitivity, and cumulative yield loss over long web lengths.

Here, we report the first demonstration of a fully R2R perovskite solar module in which serial interconnections are formed without any laser processing. Instead, interconnection and isolation are defined additively through deliberate lateral alignment during sequential slot-die coating. A fully R2R-compatible architecture is first established at the single-cell level on flexible substrates, providing a reproducible foundation for module integration. This architecture is then extended to a multi-stripe module design, where controlled layer alignment replaces post-deposition material removal as the defining interconnection mechanism. Using this alignment-driven strategy, four-stripe perovskite modules with an overall area of 10 × 10 cm² are fabricated in a continuous coating sequence. The resulting modules exhibit stable diode behavior, uniform electroluminescence across all stripes, and reproducible performance over active areas up to 40 cm². Progressive optimization of coating conditions, ink rheology, and alignment offsets leads to stabilized PCEs exceeding 5%, with predictable scaling trends governed by lateral charge transport rather than process variability. Importantly, the absence of laser scribing eliminates common sources of edge damage and debris-related degradation.

To assess the intrinsic performance potential of this laser-free architecture, distributed electrical modeling is employed to decouple geometric and material limitations. The analysis reveals that module efficiency is currently constrained primarily by the conductivity of the transparent electrode and the carbon contact, rather than by the interconnection geometry itself. Simulations show that efficiencies exceeding 9% are achievable solely through realistic improvements to the transparent conducting substrate and carbon electrode, without altering the module layout or coating sequence. This finding demonstrates that the proposed alignment-defined interconnection strategy has not yet reached its intrinsic performance ceiling.

As interconnections become embedded directly within the coating sequence, maintaining alignment fidelity over long web lengths becomes a critical determinant of yield. In this context, inline metrology and real-time process monitoring emerge as key enablers for stabilizing alignment and detecting drift during production. This study establishes laser-free, alignment-based interconnection as a viable route toward truly continuous “ink-to-module” roll-to-roll manufacturing of perovskite solar modules.