Evaluating low-cost photoactive layers for upscaling of flexible organic photovoltaic modules
Harald Ade a, Harry Schrickx b, Dawson Boone b, Abdullah Al Shafe b, Xinyung Dong a, Brendan O'Connor c
a Department of Physics and Organic and Carbon Electronics Laboratories (ORaCEL), North Carolina State University, Raleigh, NC 27695, United States
b PolyPV, LLC
c Department of MAE
Proceedings of MATSUS Spring 2026 Conference (MATSUSSpring26)
B2 Strategies to push the efficiency and stability limits of organic photovoltaics at a multiscale
Barcelona, Spain, 2026 March 23rd - 27th
Organizers: Ignasi Burgués and Maria Saladina
Invited Speaker, Harald Ade, presentation 550
Publication date: 15th December 2025

Organic photovoltaics (OPVs) have reached efficiencies exceeding 21%, but these peak performances typically rely on synthetically complex and expensive polymer donors such as PM6 or D18, rigid substrates, small active areas (<<1 cm2), and processing by spin coating. While promising, this approach presents significant barriers to commercial viability, particularly considering that the photoactive layer might constitute the majority of the projected costs of OPV module production. Our research addresses these limitations by developing processing techniques for flexible OPV modules using scalable processing with green solvents and a low-cost photoactive layer in an inverted architecture. We investigate PTQ-10 as the polymer donor, which is synthetically simpler than conventional high-efficiency donors for potentially lower cost high-volume production.  Through control of the vertical phase distribution, achieved by utilizing additives, and implementing a tailored layer-by-layer slot-die coating protocol, we increased the efficiency of inverted OPV devices. Additionally, by optimizing the photoactive layer viscosity for slot-die coating, we improved film consistency and quality, achieving active-area efficiencies exceeding 13% for flexible OPV modules larger than 10 cm2. We compare performance and stability to commercially available materials, which currently exceed PTQ10 in performance and stability. We discuss the challenges associated with PTQ10-based inks and the work required to turn it into a competitive commercially viable system. Our work nonetheless demonstrates the highest combination of performance and active area for slot-die coated flexible modules, representing a significant step toward commercially viable OPV technology.

Work supported by ONR STTR phase-II award N6833523C0036

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