Publication date: 22nd July 2026
In recent years, non-fullerene acceptor (NFA) materials have driven organic photovoltaic (OPV) efficiency from roughly 12% to certified single-junction values now exceeding 20%, with organic tandems surpassing 21%. However, these advances are most often achieved on small-area, spin-coated devices whose formulations are not readily transferable to scalable manufacturing, and which still face severe limitations in lifetime and operational stability under real-world conditions.
Closing this gap requires working on two fronts at once. Intrinsically, the organic semiconductors, formulations, and interlayers must be engineered for full compatibility with slot-die coating in roll-to-roll (R2R) production, without sacrificing the morphology behind high-efficiency blends. Extrinsically, module behaviour is equally critical: the physical and chemical compatibility of the active stack with adhesives, encapsulants, and barrier films, balanced against barrier performance, cost, and operating environment.
In this talk we present NFA-based modules and full-size panels manufactured by slot-die R2R coating, several of which are already installed and operating in outdoor environments. Drawing on this field experience, we discuss the practical requirements of moving from laboratory devices to manufacturable products, the recurring degradation modes observed under real operating conditions, and the factors that continue to slow the commercial uptake of these materials. We also consider application contexts where deployed OPV is beginning to show value, including surface temperature reduction.
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