TNO achieves breakthrough in silicon solar cell metallisation technology: fully copper-metallised silicon heterojunction solar cell

Performance of solar cells with copper-metallisation comparable to those with silver-metallisation

The new process, using the existing screen print production technology, enables the application of very narrow copper lines on both the front and back sides of the solar cells. The performance of these copper-metallised cells is within 1% of traditional silver-metallized cells.

Copper is currently 100 times cheaper and 1,000 times more abundant on the market than silver, enabling solar production to scale up sustainably without reliance on that scarce resource.

Global demand for solar energy is growing rapidly. By 2035, annual addition of PV systems could reach nearly 1 terawatt. At such a scale, up to 50% of annual global silver production would be needed for solar cells alone.

This research was carried out in close collaboration with Dutch PV start-up MCPV B.V. and a company specialising in metallisation pastes.

Next steps

TNO is continuing work on improving the copper metallisation process, developing advanced solar module technology compatible with this method, and testing the long-term reliability of the resulting modules. Because the method uses screen-printing technology, industrial implementation is expected to be relatively straightforward. Together with partners such as MCPV B.V. work is underway to ensure rapid and sustainable industrial application.

Support and Collaboration

These results were achieved with support from the SusCon project, partly funded by TKI Urban Energy, part of the Top Consortia for Knowledge and Innovation (TKIs) of the Ministry of Economic Affairs and Climate Policy, and SolarNL, funded by the National Growth Fund.