Publication date: 15th December 2025
Roll-to-roll (R2R) coating offers a fundamentally different manufacturing pathway for perovskite photovoltaics compared with sheet-based processing, enabling continuous deposition of functional inks on flexible substrates and a credible route to high-throughput “ink-in/module-out” production. In this talk we outline the practical capabilities and remaining challenges for translating flexible perovskite devices from laboratory demonstrations to full R2R fabrication, with particular emphasis on module design and interconnection strategies that consider yield, active-area usage, and electrical performance during continuous manufacture.
We discuss how scalable coating methods such as slot-die can provide thickness control and uniformity, while fully solution-processed electrodes (carbon-based top contacts) offer a pathway to ambient operation. Moving from cells to modules introduces interconnect and isolation requirements that are typically achieved via laser scribing (P1-P3) or, alternatively, through a registration-driven approach where deliberate stripe offsets define the interconnect geometry without post-deposition material removal. We consider this as a “registration window” problem, balancing stripe widths, overlaps, and isolation gaps against alignment error and edge broadening.
To conclude the talk we show that the route to flexible perovskite modules is as much about manufacturable layout and alignment tolerance as it is about materials, and we conclude with practical design rules that can be implemented on an R2R line to de-risk scale-up.
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