Publication date: 15th December 2025
Organic photovoltaic materials represent a promising low-cost renewable energy technology
due to high power conversion efficiencies, solution processability and compatibility with roll-
to-roll manufacturing. To enable high-throughput production, the development of roll-to-roll
compatible printing techniques, e.g., gravure and screen printing, is essential. Up-scaling of
device fabrication from lab-scale to large-area printed systems introduces several challenges.
Unlike coating methods such as spin coating, printing requires control of material transfer, film
thickness and process stability under continuous roll-to-roll conditions. Key limiting factors
involve rheological matching of sequential layers, processing with non-halogenated solvents
and formation of well-defined interfaces, which may suffer from morphological and electronic
limitations. As a result, device performance achieved with conventional lab-scale deposition
methods cannot be directly transferred to printed solar cells.
In this contribution, we present a strategy for successfully transitioning o-xylene-based
PM6:Y12 organic solar cells from spin coating to scalable printing. The analysis of the device
physics indicates that the main efficiency deficit stems from a lower photocurrent,
predominantly due to optical losses introduced by the thick screen-printed PEDOT:PSS layer.
Further, we found that bulk morphology is not a major driver in the decrease of performance.
We attribute the reduced open-circuit voltage to both enhanced radiative losses and increased
non-radiative recombination, whereas the lower fill factor is primarily governed by charge-
transport limitations. We further compare solar cells processed from o-xylene and chloroform,
and found that the solvent influences recombination and extraction, namely chloroform leads
to a higher open-circuit voltage and o-xylene slightly improves charge transport.
Overall, our findings show that organic solar cells can be successfully transferred to gravure-
printing, and further research should focus on printing-compatible transport layers and
minimizing charge transport losses
Svitlana Taranenko,1 Chen Wang,2 David Holzner,1 Robert Eland,1 Christopher Wöpke,2.
Toni Seiler,2 Alexander Ehm,2 Fabio Le Piane,2 Roderick C. I. Mackenzie,3 Dietrich R. T. Zahn,2
Carsten Deibel,2 Arved Carl Hübler,1 and Maria Saladina2
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