Printed organic photovoltaics modules with enhanced efficiency and over 10 years of expected lifetime

Organic photovoltaics (OPV) have emerged as a promising solution for sustainable energy applications, offering flexibility, low toxicity, and facile integration into innovative products. However, bridging the performance gap between lab-scale cells and industrial panels remains critical for achieving a cost-competitive technology. This study introduces a novel active layer ink formulation developed by Brilliant Matters that demonstrates high batch-to-batch reproducibility and lab-scale PCEs exceeding 11.4% with enhanced stability. Through rigorous lab-to-fab validation, the ink was successfully adapted to blade-and slot-die coating techniques, ultimately achieving fully-printed commercial panels manufactured at Oninn that exhibited an average PCE of 5.5%, with excellent long-term stability under accelerated aging tests (ISOS-L-2). Performance remained robust under real-life conditions, supporting a projected long panel lifetime. These results represent a 55% performance increase over existing commercial inks and demonstrate the scalability of BM’s formulation for industrial OPV production. This study underscores the potential for further bridging the efficiency gap with silicon PV technologies, paving the way for cost-effective, high-performance OPV solutions.