Publication date: 15th December 2025
The transition of perovskite photovoltaics toward industrial roll-to-roll (R2R) manufacturing relies on scalable deposition routes and ink formulations capable of ensuring uniformity, mechanical resilience, and long-term stability. Building on recent advances in tailored perovskite inks for scalable processes and the mechanistic insights into flexible device robustness (1), in this study we demonstrate the successful roll-coating of one-meter-long perovskite films on polymeric substrates with high morphological uniformity.
Using a pre-industrial roll-coater engineered to emulate continuous R2R operation, we optimize roll speed, slot die coating parameters, solution rheology, and gas quenching to obtain perovskite layers with thickness uniformity of 550nm along the full meter. These process conditions, aligned with guidelines emerging from our recent studies on scalable ink rheology and interfacial engineering, enable reproducible film formation with suppressed defect formation and controlled crystallization dynamics (2). Compared to batch-processed references, roll-coated perovskite layers show delayed crack initiation and improved adhesion to transport layers. This behavior is consistent with recent observations on mechanically tolerant perovskite microstructures and elastomer-modified interfaces (3) (4). Overall, this work represents the first demonstrations of meter-scale perovskite deposition via roll coating, linking advanced ink design, scalable processing, and mechanical robustness. The results provide a practical framework to accelerate the translation of perovskite solar technologies toward continuous, industrially relevant R2R fabrication of flexible devices.
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This project has received funding from the European Union's Framework Programme for Research and Innovation Horizon Europe (2021-2027) under the Marie Skłodowska-Curie Grant Agreement No. 101068387 “EFESO”.
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