SBIR Phase I: Perovskite Solar Cells on Metal Foil Substrates: Enabling Low-Cost and Flexible Solar Technology

The broader/commercial impact of this Small Business Innovation Research Phase I project will be the development of a lightweight, flexible, and potentially recyclable solar manufacturing approach that can expand the range of applications for solar energy. Conventional solar panels are rigid and heavy, which limits installation on many rooftops and structures. This project will investigate a new approach for making solar cells directly on metal foil, with the goal of reducing manufacturing cost, lowering installation burden, and enabling new applications such as portable power and power generation on weight-sensitive surfaces. If successful, this technology could strengthen U.S. energy dominance, and support advanced manufacturing jobs. This Small Business Innovation Research Phase I project will focus on a high-risk approach for fabricating perovskite solar cells directly on metal foil substrates instead of conventional glass or plastic-based platforms. The key technical risk is that metal foil surfaces are significantly rougher and more difficult to process, which can introduce defects, reduce charge transport, and limit device stability. A second major challenge is the development of a transparent top electrode that allows light to enter the device efficiently while maintaining electrical conductivity. The project will advance the field by developing interface engineering strategies, thin-film deposition methods, and transparent contact designs for flexible perovskite photovoltaics. The scope of the work includes three main objectives: improving the metal foil surface to support high-quality thin-film growth, integrating efficient transport and absorber layers onto the metal substrate, and evaluating pathways for transparent top contact formation and substrate reuse. The methodology will include tasks related to substrate surface treatment, slot-coating of functional layers, controlled film formation, and electrical and stability testing of completed devices. Successful completion of this work will establish the feasibility of a scalable manufacturing pathway for flexible perovskite solar cells compatible with roll-to-roll production. This award reflects NSF's statutory mission and has been deemed worthy of support through evaluation using the Foundation's intellectual merit and broader impacts review criteria.