Publication date: 5th November 2025
The rise of all-printed carbon-based perovskite solar cells marks a paradigm shift toward scalable and sustainable next-generation photovoltaics. Especially when adopting a hole-transport-layer-free design, both processing steps and cost are reduced, while long-term operational stability is significantly improved. Within this context, piezoelectric drop-on-demand inkjet printing can be employed as a powerful enabler for scalability, reproducibility, sustainability and digital precise fabrication route. Building upon this foundation and advancing from proof-of-concept devices to manufacturable solar modules, this work demonstrates a fully ambient-air processed and high-throughput production route for perovskite technology. Inkjet printing is employed as the primary deposition technique for nearly all functional layers. Special attention has been paid to the development of a perovskite precursor ink, derived from centimeter-scale single crystals, formulated with low-lead composition, using industrial-grade reagents, and processed in a green solvent, with its colloidal stability exceeding three months under dark storage. Through the optimization of this perovskite precursor ink and drying dynamics, the mitigation of the coffee-ring effect is attained, resulting in a uniform, defect-free perovskite active layer, which is an essential prerequisite for high-quality photovoltaic devices. Complementarily, a new carbon paste is also proposed, engineered for efficient charge transport and back-contact layer, which is applied using blade coating for the scalable fabrication of carbon electrode, ensuring uniform film formation, while maintaining full compatibility with printing-based device assembly. Upscaling from laboratory-scale cells to module-level devices demonstrated high efficiency and cost-effectiveness, with efficiencies exceeding 12% on 1500 cm2 (upscaling loses 8<%reldec−1, geometrical fill factor ≈70%), and the “bill of materials” and efficiency-adjusted specific costs to be estimated on the order of 30 €/m² and 0.5 €/Wp, respectively.
The work is supported by the action: "Promotion of quality, innovation and extroversion in universities (ID 16289)", "SUB1.1 Clusters of Research Excellence - CREs" and funded by the Special Account of the Ministry of Education, Religious Affairs and Sports within the framework of the National Recovery and Resilience Plan “Greece 2.0”, with funding from the European Union – NextGenerationEU and co-financing from national resources (National Public Investments Program – VAT contribution).
