Publication date: 21st July 2025
Commercialization of perovskite photovoltaics (PPVs) hinges on the successful transition from laboratory-scale fabrication to industrial-scale manufacturing. Gas-quenching-assisted blade coating (GABC) has emerged as a promising strategy for high-throughput deposition of perovskite films. However, challenges remain in controlling crystallization kinetics and achieving uniform film morphology. Particularly, the formation of voids at the substrate/perovskite interface hinders the fabrication of thick perovskite layers compatible with fully printable devices with non-reflective carbon electrodes. This talk focuses on advancing fab-scale production of PPVs, showcasing a successful transition from lab-scale fabrication to GABC. By integrating in situ optical spectroscopy with doctor-blade coating, we first reveal the critical role of gas quenching in modulating nucleation kinetics and enabling compact, dense perovskite layers. Furthermore, we identify the gas-quenching stage as pivotal for α-phase FAPbI₃ nanocrystal nucleation under ambient conditions, which is essential for producing highly crystalline and stable perovskite films after annealing. Spontaneous cesium ion incorporation from cesium chloride further facilitates nucleation and nanocrystal growth, enabling fully printed devices with power conversion efficiencies (PCEs) of up to 19.36% and minimodules reaching 16.23%. Finally, to address the optical limitations of carbon electrodes in light recycling, we introduce a two-dimensional perovskite layer-assisted growth (2D-LAG) strategy. This approach mitigates void formation in perovskite films over 1 μm thick by promoting heterogeneous nucleation and suppressing solvent entrapment. The resulting monolithic, void-free films achieve PCEs of 19.9% on rigid substrates and 17.5% on flexible substrates in fully printed perovskite solar cells with non-reflecting carbon electrodes.
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