The solar PV industry has undergone a shift from doped amorphous silicon to microcrystalline silicon, which has become a standard. The next frontier lies in metallization cost reduction. Manufacturers are moving in 3 key directions: increasing the number of busbars and eventually eliminating them through zero-busbar (ZBB) designs; lowering the paste laydown by reducing the finger width and reducing the silver consumption by lowering the silver loading; and ultimately going silver-free. Companies are also focusing on high mobility TCO material used in HJT processing.

BC technology is more opaque compared to its peers due to the proprietary nature of its development. However, insights from industry leaders like LONGi, AIKO, and SPIC reveal shared themes. BC is a platform that can be based on various cell architectures. However, the majority of manufacturers are using bipolar passivated contacts. Laser technology plays a vital role in BC solar cell manufacturing, particularly in enabling the rear-side structuring that defines this architecture. While there have been some growing pains with lasers in the beginning, today’s laser can very well support the throughput as well as quality requirements of BC cell makers.

When it comes to metallization, all major BC manufacturers are actively exploring ways to reduce or replace silver, with a clear focus on copper-based solutions. And adopting ZBB is a common strategy to reduce silver consumption.

At the module level, the industry is witnessing a shift from a ‘one-size-fits-all’ approach to products to application-specific designs. Module manufacturers are now tailoring their BOMs to meet the diverse demands of different climates, installation environments, and system configurations. As a result, almost every traditional component – be it glass, encapsulant type, backsheet, or frame – has an alternative, enhancing the application and integration spectrum of PV.

This report offers a high-level overview of such developments. It brings together the major technology pathways, manufacturing adjustments, and material trends shaping today’s advanced solar cell and module production. The insights are based on interviews, presentations, and contributions from key industry players.