Boosting Uptime and Throughput in Perovskite Solar Cell Manufacturing
How a leading solar manufacturer improved monitoring time, process control, and productivity
A major solar cell manufacturer was facing reduced tool uptime due to the challenging nature of perovskite materials. The harsh process environment shortened then quartz crystal microbalance (QCM) monitoring lifetime, leading to increased maintenance and limiting overall production capacity.
To mitigate downtime, the manufacturer had previously upgraded its tools with the INFICON Crystal 12® rotary sensors, allowing for automated crystal switching and quick, tool-free carousel replacements. While this solution extended tool runtime, the company needed additional strategies to further maximize productivity.
Uncovering a Key Opportunity for Improvement
During a review with INFICON application experts, it became clear that the QCMs in use featured gold electrodes, which are a good match for low-stress metals but not ideal for corrosive perovskite environments. INFICON recommended switching to alloy electrode QCMs because they offer up to four times longer monitoring life under harsh conditions. The customer tested the alloy versions and quickly saw a marked improvement in sensor longevity.
The manufacturer’s engineering team was using an active oscillator controller, chosen early on for its low cost and sufficient performance during initial production phases. However, with rising solar cell demand and more advanced process requirements, it was time for an upgrade. INFICON recommended the Cygnus® 2 deposition controller with ModeLock® technology, which provides:
- 10 times higher resolution
- 4 times longer QCM monitoring time
- Improved process control for next-generation cell production
The improved resolution and monitoring life offered by the Cygnus 2 controller aligned perfectly with the company’s goals for operational efficiency and product quality.
The Result: Increased Productivity and Reliability
Following a successful installation and training period, the manufacturer experienced a significant boost in tool uptime and throughput. The combination of longer-lasting QCMs and a higher-performance controller helped reduce maintenance interruptions and better support the company’s next-generation solar cell manufacturing process.