Screen-printed pattern positioning accuracy affected by the mechanical properties of screen mesh

Silicon solar cells achieve high efficiency through the precise patterning of finger electrodes onto targeted areas. Positioning accuracy is crucial in metallization. In screen printing, a critical metallization process, the pattern accuracy is affected by various parameters including the deformation of screen meshes. This study quantitatively evaluates how variations in the mechanical properties of screen meshes—such as differences in mesh materials and calendering—affect the positioning accuracy of screen-printed patterns, using both screen printing experiments and deformation simulations. Meshes with higher elastic and shear moduli and isotropic mechanical properties in the warp and weft directions exhibited less deformation and better positioning accuracy. Further improvements in positioning accuracy during screen printing can be achieved by investigating methods to reduce mesh deformation, such as modifying mesh weaving structures, adjusting screen tension, and optimizing material properties and the calendering process, with the goal of enhancing the efficiency of silicon solar cells. • The mechanical properties of a screen mesh affect the positioning accuracy of screen-printed patterns. • Increasing the rigidity of a screen mesh improves the positioning accuracy of screen-printed patterns. • Eliminating anisotropy in mechanical properties between the warp and weft directions of a screen mesh improves the positioning accuracy of screen-printed patterns. • Screen mesh deformation was simulated using FEM analysis to assess the effects of mechanical on the printing results.