NREL and Ampulse apply CVD process to create c-Si thin-film solar cells

Facebook
Twitter
LinkedIn
Reddit
Email

A trio of companies is attempting to reduce the waste caused by wafer-sawing processes by growing crystalline silicon on relatively cheap foil. NREL has teamed up with DOE's Oak Ridge National Laboratory (ORNL) and c-Si thin-film technology company Ampulse with the aim of lowering the cost of solar panels.

The teams will use a chemical vapour deposition (CVD) process to grow high-quality silicon in thin layers on a metal foil developed by ORNL. Ampulse will design a full-scale production line that will support the long rolls of metal foil necessary to ensure the technology’s cost-effectiveness and will install the line in NREL's Process Development Integration Laboratory (PDIL).

This article requires Premium SubscriptionBasic (FREE) Subscription

Unlock unlimited access for 12 whole months of distinctive global analysis

Photovoltaics International is now included.

  • Regular insight and analysis of the industry’s biggest developments
  • In-depth interviews with the industry’s leading figures
  • Unlimited digital access to the PV Tech Power journal catalogue
  • Unlimited digital access to the Photovoltaics International journal catalogue
  • Access to more than 1,000 technical papers
  • Discounts on Solar Media’s portfolio of events, in-person and virtual

Or continue reading this article for free

Today’s c-Si technology manufacturing process involved huge levels of wastage, as around half of the refined silicon is lost as dust in the wafer-sawing process. Furthermore, the wafer-sawing process can render incompatible as many as 6,000 wafers from a 2m boule of silicon. Wafers cut in this way are usually close to 10 times thicker than they need to be in order to convert the maximum amount of sunlight to electricity.

The Ampulse process does not require the creation of a feedstock, but works directly with the silane to grow the desired amount of silicon directly onto the foil substrate.

“[The process] goes straight from pure silicon-containing gas to high-quality crystal silicon film,” says Brent Nelson, operational manager for the PDIL at NREL. “The advantage is you can make the wafer just as thin as you need it — 10 microns or less.”

Further information on the collaborative effort is available here.

Read Next

July 10, 2025
German renewables company BayWa r.e. has secured a €3 billion (US$3.5 billion) loan for 'operational initiatives and pipeline expansion.'
July 10, 2025
US renewables developer Invenergy has launched commercial operations of 250MW Fairbanks Solar Energy Center in Sullivan County, Indiana. 
July 10, 2025
US solar residential installer Sunnova has entered into a stalking horse asset purchase agreement with Omnidian for some of its assets.
July 10, 2025
A report published by the US Department of Energy (DOE) this week claims that the previous government’s support for renewable energy could cause blackouts to “increase by 100 times” by 2030.
July 10, 2025
UbiQD has signed a supply agreement with First Solar to supply its fluorescent quantum dot technology for use in the latter’s PV panels.
July 10, 2025
Copenhagen Energy has partnered with Thy-Mors Energi to set up a 100MW PV and BESS project in Ballerum, about 370km from Copenhagen. 

Subscribe to Newsletter

Upcoming Events

Media Partners, Solar Media Events
September 2, 2025
Mexico City, Mexico
Solar Media Events
September 16, 2025
Athens, Greece
Solar Media Events
September 22, 2025
Bilbao, Spain
Solar Media Events
September 30, 2025
Seattle, USA
Solar Media Events
October 1, 2025
London, UK