The Future of Thin-Film and Organic Photovoltaics Manufacturing

Table of Contents

• E.1 Key Trends in Thin-Film and Organic Photovoltaics Manufacturing
  • E.1.1 Opportunity #1: Ramping Up TFPV Manufacturing Capacity
• E.2 Implications and Opportunities for Manufacturing Equipment Firms
  • E.2.1 Opportunity #2: Selling Machinery for R2R and Flexibility
  • E.2.2 Opportunity #3: Improving Printed PV
  • E.2.3 Opportunity #4: Improved Classical Deposition Techniques
  • E.2.4 Opportunity #5: Beyond Proprietariness-“Off-the-Shelf” Equipment?
• E.3 Implications and Opportunities for Materials Firms
  • E.3.1 Opportunity #6: New Processes Need New Materials
• E.4 Manufacturing-Related Opportunities for Solar Panel Makers
• E.5 Key Innovators in Organic and Thin-Film Photovoltaics Manufacturing
• E.6 Summary of Manufacturing Capacity Forecasts and Equipment Shipments

• 1.1 Background to this Report
  • 1.1.1 Perspective # 1: Manufacturing and PV Conversion Efficiencies
  • 1.1.2 Perspective #2: Manufacturing and Cost Reduction
  • 1.1.3 Perspective #3: Manufacturing and Intellectual Property
  • 1.1.4 Perspective #4: Integrated Approaches to Manufacturing
• 1.2 Objectives and Scope of this Report
• 1.3 Methodology and Scope of this Report
• 1.4 Plan of this Report

• 2.1 Introduction
  • 2.1.1 TFPV/OPV Patterning Trends and Laser Scribing
• 2.2 Batch Processing and the Evolution to R2R Fabrication and Flexible Substrates
  • 2.2.1 Flexibility, Substrates and TFPV
  • 2.2.2 R2R Everywhere
• 2.3 Potential of Novel Fabrication Techniques in Thin-Film/Organic PV Manufacturing
  • 2.3.1 The Future of Sputtering
  • 2.3.2 PECVD and its Variations
  • 2.3.3 Other Vapor Deposition Approaches
  • 2.3.4 Printing and Solution Processing
  • 2.3.5 Proprietary Techniques and Development of Proprietary Equipment
• 2.4 Impact of New Materials on Manufacturing
  • 2.4.1 New PV Materials
  • 2.4.2 Contact Materials
  • 2.4.3 Encapsulants
• 2.5 Health, Safety and Environmental Concerns in the PV Factory
  • 2.5.1 Health and Safety Issues
  • 2.5.2 Environmental Issues
  • 2.5.3 Issues Related to Nanomaterials
• 2.6 Summary and Analysis of Current Manufacturing Performance
  • 2.6.1 Yields
  • 2.6.2 Throughput and Economies of Scale
  • 2.6.3 Energy Conversion Efficiency Achievements
• 2.7 Key Points Made in this Chapter

• 3.1 Approaches to a-Si and Nanosilicon Cell Manufacturing
  • 3.1.1 A Note on Silicon Nanomaterials
  • 3.1.2 Note on HIT Cells
  • 3.1.3 Manufacturing Profile A: EPV Solar
  • 3.1.4 Manufacturing Profile B: Flexcell
  • 3.1.5 Manufacturing Profile C: Innovalight
  • 3.1.6 Manufacturing Profile D: PowerFilm
  • 3.1.7 Manufacturing Profile E: Sharp
  • 3.1.8 Manufacturing Profile F: Uni-Solar
• 3.2 Approaches to CIGS Cell Manufacturing
  • 3.2.1 Printing, Vacuum Deposition and CIGS
  • 3.2.2 CIGS: Cell Structures, Materials and Manufacturing
  • 3.2.3 Manufacturing Profile G: DayStar Technologies
  • 3.2.4 Manufacturing Profile H: Global Solar
  • 3.2.5 Manufacturing Profile I: HelioVolt
  • 3.2.6 Manufacturing Profile J: Miasole
  • 3.2.7 Manufacturing Profile K: Nanosolar
• 3.3 Approaches to CdTe Cell Manufacturing
  • 3.3.1 Manufacturing Profile L: First Solar
• 3.4 Approaches to OPV Cell Manufacturing
  • 3.4.1 Manufacturing Profile M: Konarka Technologies
  • 3.4.2 Manufacturing Profile N: G24 Innovations
• 3.5 Key Points Made in this Chapter

• 4.1 Introduction and Forecasting Methodology
  • 4.1.1 Forecasting Capacity
  • 4.1.2 Forecasting Equipment
  • 4.1.3 Changes from Previous NanoMarkets Reports
  • 4.1.4 Data Sources
• 4.2 Eight-year Capacity Forecasts by Type of Material Processed
  • 4.2.1 Amorphous Silicon
  • 4.2.2 CIS/CIGS
  • 4.2.3 CdTe
  • 4.2.4 OPV
  • 4.2.5 Summary of Capacity Forecasts
• 4.3 Eight-year Capacity Forecasts by Type of Manufacturing Equipment Used
  • 4.3.1 Assessment of Total Capital Expenditure by the TFPV and OPV Sectors
  • 4.3.2 a-Si Equipment
  • 4.3.3 CIS/CIGS Equipment
  • 4.3.4 CdTe Equipment
  • 4.3.5 OPV Equipment
• 4.4 Summary of OPV/TFPV Equipment Forecasts by Material and Equipment Type
• 4.5 Geographical Forecasts of TFPV/OPV Capacity

• About the Author

List of Exhibits

• Exhibit E-1: TFPV/OPV Capacity and Equipment Expenditures
• Exhibit 2-1: OVPD Versus Thermal Evaporation
• Exhibit 2-2: Comparison of Common Printing Processes
• Exhibit 2-3: Comparison of Inkjet Technologies
• Exhibit 2-4: Inkjet Equipment Suppliers
• Exhibit 3-1: Manufacturing Approaches Adopted by CIGS Solar Panel Firms
• Exhibit 3-2: Organic Solar Cell Manufacturing
• Exhibit 3-3: Properties of Konarka' s Power Plastic OPV-based Material
• Exhibit 3-4: Konarka' Applications Partners
• Exhibit 3-5: Konarka' s OPV-based Material Targets for 2010
• Exhibit 4-1: Amorphous Silicon PV: Capacity Ramp Up
• Exhibit 4-2: Worldwide Production Capacity for a-Si TFPV
• Exhibit 4-3: CIS/CIGS PV: Capacity Ramp Up
• Exhibit 4-4: Worldwide Production Capacity for CIS/CIGS TFPV
• Exhibit 4-5: Short-Term Expansion of CdTe TFPV Capacity
• Exhibit 4-6: Worldwide Production Capacity for CdTe TFPV
• Exhibit 4-7: Worldwide Production Capacity for OPV (Including Dye Sensitive Cells)
• Exhibit 4-8: Worldwide Production Capacity for Thin-Film and Organic PV (Including Dye Sensitive Cells) (MWp)
• Exhibit 4-9: Worldwide Production Expenditures on Equipment for TFPV and Organic PV (including Dye Sensitive Cells)
• Exhibit 4-10: Worldwide Market for a-Si and Nanosilicon PV Processing Equipment
• Exhibit 4-11: Worldwide Market for CIS/CIGS PV Processing Equipment
• Exhibit 4-12: Worldwide Market for CdTe PV Processing Equipment
• Exhibit 4-13: Worldwide Market for OPV Processing Equipment (Including Equipment for Dye Sensitive Cells)
• Exhibit 4-14: Worldwide Addressable Market for Third-Party OPV/TFPV Processing Equipment: By Type of Material Processed ($ Millions)
• Exhibit 4-15: Worldwide Market for OPV/TFPV Processing Equipment by Type ($ Millions)
• Exhibit 4-16: Worldwide TFPV/OPV Production Capacity by Region (MWp)