“According to Daniel Clark, 3D printing has the potential to revolutionize the solar sector.” The entrepreneur is the founder of T3DP, a solar energy startup with many patents in volumetric solar energy and 3D printing.
I chatted with Clark about the progress additive manufacturing is making in the creation of next-generation photovoltaics, as well as the technology’s potential to usher in a new era of solar energy.
Solar power, combined with wind, contributed for more than 90% of the renewable energy sector’s growth in 2020, according to BP’s most recent Statistical Review of World Energy. This expansion is reflected in the sector’s increasing market value, with the worldwide solar energy industry predicted to reach $422 billion in 2022, up from $86 billion in 2015.
Solar continues to be the third-largest renewable electricity technology behind hydropower and onshore wind, with power generation increasing by a record 23% in 2020 compared to 2019.
While the technology has certain advantages, such as helping individuals save money on their bills and become energy independent, it also has some disadvantages, such as high upfront costs, significant area needs, and the environmental effect of manufacturing photovoltaic panels. In fact, a single silicon solar panel consumes 130 liters of oil, and by 2050, an estimated 78 million metric tons of harmful solar panel trash will be disposed of in landfills.
Several years ago, there was a flurry of activity in the additive manufacturing sector involving the 3D printing of more efficient, low-cost photovoltaics, sparked by different solar power innovation contests sponsored by the US Department of Energy, among others. Since then, however, there appears to have been a slowdown in this sector.
The Chemistry of Thin Film Materials (CTFM) laboratory at the University of Erlangen in Germany has announced a funding from the European Research Council (ERC) to rapidly prototype solar cells utilizing their atomic-layer additive manufacturing technology. With the aid of ATLANT 3D Nanosystems, the winner of the Formnext Start-up Challenge 2021, the lab wants to bring the solar cells to market.
Clark’s California-based start-up T3DP, which has been using its proprietary volumetric 3D printing technology to create perovskite-based solar panels since 2019, is one company that has stayed very active in this space.
T3DP has developed a new solar cell based on the honeycomb structure of insect eyes that can capture three times more energy for half the price of standard silicon-based cells. By reusing glass from abandoned solar panels, the technology also permits micro-solar cells to be created at a carbon-neutral level.
“Volumetric 3D printing has the potential to transform the solar business by doubling or tripling the power output of flat silicon panels,” Clark says.
A standard flat solar panel generates 200 watts per square meter, however our designs can generate 400-600 watts in the same space.
By curing products in a single step rather than layer by layer, volumetric 3D printing can overcome the limited throughput, geometric constraints, structural faults, and scalability difficulties that are often associated with additive manufacturing.
Clark collaborated with Alexander Lippert, an Associate Professor of Chemistry at SMU, to develop and market the 3D Light PAD, a unique volumetric 3D printer developed exclusively for the 3D printing of a wide range of complicated components for solar cell manufacture.
The printer creates high-resolution 3D components by employing a photoswitchable photoinitiator to drive polymerization to locations exclusively at the junction of two different wavelengths of light. T3DP has formed a strategic partnership with AsterTech, a company that has developed an aerosol-jet-assisted perovskite deposition method for fabricating high-quality solar cells on the complex surfaces SMU and Clark created with their 3D Light PAD printer in collaboration with the Air Force Research Laboratory (AFRL).
After a four-year application process, Clark’s volumetric 3D printing patent was awarded last year, and the IP is currently being used by volumetric 3D printing start-up xolo.
While Clark is unable to discuss real-world application possibilities due to a non-disclosure agreement (NDA) with xolo, he says: “While volumetric 3D printing technology is amazing, it will be two to three years before we see any major mainstream uses.” The printer, on the other hand, is the starting point for my new Subzero Molding and Embossing technology, which will allow us to mass-produce our micro 3D solar cell substrates from recycled solar panel glass.
“We have some new patents from Lightfield Labs’ Solid Light, including a revolutionary True Volumetric Display.”
Lightfield Labs is working on next-generation holographic display technologies, with financing from companies like Bosch, which, according to Clark, will be interested in the LightPAD 3D printer and its pending patents in the future.
Clark’s Sub Zero Manufacturing method is developed for the mass manufacturing of flexible optically flawless solar cell substrates from recycled solar panel glass that don’t need to be polished. The broken recycled glass is mixed with Glassomer UV Curable Resin and Tethon 3D Genesis Development Resin before being “punched into a 3D spiked pyramid shape inscribed with ultra-small tiny LEDs.”
According to Clark, the approach is “thousands of times faster than 3D printing alone,” and he believes it might be used to enhance the semiconductor industry’s green footprint.
“The contemporary silicon solar sector is dominated and controlled by China,” Clark says of the current situation of the solar energy generation business. Last October, the price of silicon increased by 300 percent in 7-8 weeks. As this upward tendency continues, I see a potential for the Western world to rekindle a dormant flame through enhanced manufacture of aesthetically pleasing solar that will be difficult to imitate.
“I believe that our sophisticated one-step Volumetric 3D Printing and unique Subzero Forming methods will produce a synergistic dichotomy that will bring solar manufacturing power back to the EU, the United States, and the Western world.”
Clark also works for Villara Energy Systems, the company behind the VillaGrid energy storage system, which claims to provide greater power, safety, and longevity than typical residential batteries. While the company isn’t now using Clark’s volumetric 3D printing technique, he believes the procedure could one day aid mass manufacturing of batteries and solar cells at the company’s battery and solar manufacturing facilities in Sacramento County, California.
Are you interested in a job in additive manufacturing? For a list of 3D printing job openings, go to 3D Printing Jobs. You can also follow us on Twitter and like us on Facebook to stay in touch.
T3DP’s featured image depicts a hexagonal portion of a larger solar panel. T3DP provided the image.
Is it possible to print solar panels in three dimensions?
3D printing technology has been used in a variety of industries, including aerospace and robotics, due to the diversity of the process and the products it can make. The growth of 3D printing in the solar business has also helped to make it more economical and efficient, resulting in a higher rate of adoption of solar technology. Though the expense of solar energy is still out of reach for most households, the industry’s adoption of 3D printing could help to change that.
However, there are a number of ways it could assist in making solar products more accessible. Here’s how 3D printing can help the solar sector reach a wider audience.
It has the potential to increase productivity.
The use of 3D printing in the solar sector can improve efficiency in a variety of ways. One of the most obvious methods is through speed. Solar panels made with 3D printing require a lot less time to make than solar panels made with traditional methods. The construction of the cells of the panel, which used to take hours, may now be completed in a matter of minutes. This is especially useful for companies who wish to produce a variety of prototypes because they won’t have to wait as long for testing.
In terms of manufacturing materials, 3D-printed solar panels are far more efficient than conventional panels. Solar panels are frequently produced with poisonous minerals that are mined, endangering the health of the soil in the locations where they are dug. Not only that, but the panels themselves are rather expensive to produce. Solar sector experts have been looking for new ways to produce their products, and 3D printing is the perfect solution. It allows you to make solar panels out of a variety of materials without sacrificing functionality.
In fact, 3D-printed solar cells are more favorable than traditional photovoltaic (PV) cells used in solar panels since they can absorb more sunlight. 3D cells are far more precise than 2D cells, in addition to weighing less and being less complex. As a result, Massachusetts Institute of Technology researchers believe that 3D solar panels are around 20% more efficient than traditional solar panels, owing to their ability to absorb more solar energy.
Given all of these reasons, 3D printing will almost certainly result in more efficient solar panels. Companies will be able to mass-produce solar panels with fewer resources and provide consumers with a better alternative for absorbing more energy as a result of the cheaper cost of manufacture.
It has the potential to reduce the size of solar devices.
Though solar energy is typically thought of as a source of power for homes, the adaptability of 3D printing may allow it to be used in a variety of different applications. Because of the precision of 3D printing, thin solar cells that are small and light enough to be connected to materials other than glass, such as plastic or fabric, could be created. Companies would be able to contemplate making flexible solar panels as a result of this.
As a result, this invention may increase the appeal of 3D-printed solar items. It could pave the way for interesting innovations in other sectors, such as permitting solar spray to be used on commercial or residential constructions, thanks to lightweight and flexible 3D solar cells. This would allow residents to benefit from solar energy without having to install PV panels on their roofs, which would be less appealing.
It is Less Expensive
While the majority of the cost of solar panels is in the installation, 3D printing has the potential to assist lower costs in another important area: production. Solar panel manufacturers might save up to 50% on production costs by embracing 3D printing technology. Because 3D printing is so exact and controlled, businesses would be able to eliminate the waste that comes with traditional manufacturing. This prevents them from squandering costly materials like glass or polysilicon.
Furthermore, because 3D printing can be done almost everywhere, businesses would be able to obtain solar products without having to rely on distant warehouses. This would help compensate for the high shipping costs of delivering standard PV cells.
Is it possible to print solar panels?
The material that holds the photovoltaic material in classic solar cells is usually more expensive than the photovoltaic material itself. Solar cells can be printed on paper using inkjet printing. Solar cells will be more cheaper as a result, and they will be able to be placed practically anyplace. Solar cells in blinds, in windows, in drapes, and almost anywhere else in the house will be possible thanks to paper thin solar cells or, eventually, direct 3D printing. This seems pretty promising and could be the way solar energy is used in the future.
What kind of material is utilized to make solar panels?
There are numerous variations on the above strategy that result in increased efficiency, cheaper costs, or both. Some techniques have already been commercialized, while others are making their way from the lab to the manufacturing floor.
Diffusion of Phosphorus
To generate the emitter in screen-printed solar cells, a simple homogeneous diffusion is used, where the doping is the same beneath the metal contacts and between the fingers. A high surface concentration of phosphorus is required below the screen-printed contact to maintain low contact resistance. However, because of the high phosphorus concentration on the surface, a “dead layer” forms, which lowers the cell blue response. Newer cell designs can make contact with shallower emitters, which improves the blue response of the cell. Selective emitters with greater doping below the metal contacts have also been proposed 1, 2 – and are already being manufactured commercially.
Texturing the Surface to Reduce Reflection
By etching pyramids on the wafer surface using a chemical solution, wafers cut from a single crystal of silicon (monocrystalline material) can readily be textured to reduce reflection. While such etching is optimal for monocrystalline CZ wafers, it is only partially successful on the randomly oriented grains of multicrystalline material since it relies on the correct crystal orientation. Using one of the following methods, various schemes have been proposed to texture multicrystalline materials:
- Cutting tools or lasers are used to mechanically texturize the wafer surface 3, 4, 5.
- Chemical etching that is isotropic and depends on flaws rather than crystal orientation 6;
- combining isotropic chemical etching with a photolithographic mask 7, 8;
- etching with plasma 9.
- Fire Through Contacts and Antireflection Coatings
Antireflective coatings are very useful for multicrystalline materials that are difficult to texture. Titanium dioxide (TiO2) and silicon nitride are two common antireflection coatings (SiNx). Simple procedures such as spraying or chemical vapour deposition are used to apply the coatings. Dielectric coatings can increase the electrical properties of the cell by surface passivation, in addition to the visual benefits. The metal contacts can fire through the antireflection layer and attach to the underlying silicon by screen-printing a paste containing cutting agents over the antireflection covering. This method is straightforward and has the added benefit of contacting shallower emitters 10.
Edge isolation can be achieved using a variety of techniques such as plasma etching, laser cutting, or masking the border to prevent diffusion along the edge in the first place.
A back surface field (BSF) is created by printing a whole aluminum layer on the back of the cell and then alloying it by fire. This enhances the cell bulk by gettering. However, aluminum is costly, and solderable contact necessitates a second print of Al/Ag. In most cases, the rear contact is formed by printing an Al/Ag grid in a single step.
Screen printing has been utilized on a wide range of materials. Screen-printing is appropriate for lower-quality substrates like multicrystalline material and CZ due to the simplicity of the sequence. Larger substrates – up to 20 20 cm2 for multicrystalline materials and wafers as thin as 150 m – are becoming more common.
A close-up of a screen used to print a solar cell’s front contact. Metal paste is driven through the wire mesh at uncovered places during printing. The minimum width of the fingers is determined by the wire mesh size. Finger widths range from 100 to 200 millimeters.
A close-up of a screen-printed solar cell in its final state. The fingers are spaced around 3 mm apart. During encapsulation, an additional metal contact strip is connected to the busbar to reduce cell series resistance.
A completed screen-printed solar cell from the front. The multiple grain orientations are visible because the cell is made from an older multicrystalline substrate. The grains in newer multicrystaline cells are finer and less visible. A multicrystalline substrate’s square shape makes it easier to pack cells into a module.
What is the most effective method of 3D printing?
Using a 3D printer for personal projects is more efficient and effective than using a traditional printer. However, unless you are well-versed in 3D printing and its applications, you may have some difficulty producing a sturdy 3D print. You may change a lot of parameters on your 3D printer to get a high-quality, durable print. Here’s how to use them to generate robust 3D printouts.
Increase Infill Density
Increasing the inner density of a 3D print is one technique to improve its robustness. The inner density varies from 0% to 100%, with zero indicating total hollowness and 100 indicating total solidity.
A 100 infill density should theoretically make your 3D print highly strong. However, almost all designers have discovered that anything above 70% has a lower impact on the 3D print’s robustness. Instead, filament usage, printing time, expense, and stress on the 3D printer have all increased dramatically.
Note: For strength, use at least a 20% infill density and, if possible, adjust the wall thickness (described below) before increasing the infill density.
Increase Wall Thickness
“Wall Line Count” and “Outer Line Width” are used to determine the thickness of a 3D printed material’s wall. It demonstrates how thick the wall is, and how to build robust 3D prints by raising it. Because 3D printed items are more stressed on the outside than the inside, increasing wall thickness will improve strength.
Increased wall thickness not only strengthens the printed material, but it also improves overhangs (difficult-to-print geometry forms in 3D models) and water tightness.
Note: A normal product must have a wall thickness of at least 1.2mm. Then you can boost it for additional power.
Use Thinner Layers
The use of a thin layer improves adhesion and density between following layers, resulting in stronger 3D printed items. According to designers, going as small as 0.1mm (100 microns) will optimize strength. There is, however, a corresponding increase in printing time.
Use a Strong Infill Pattern
Using the right infill pattern is another approach to reinforce 3D printers. Infill patterns are used in conjunction with infill density to provide an interior support structure for 3D printing. They also provide the portion some rigidity and prevent wall deformation. When it comes to making sturdy 3D prints with infill patterns, a dense infill pattern of 30-50 percent is recommended.
The strength of your 3D print is also determined by the type of infill pattern you employ. The following are three infills to consider:
Triangular Infill Pattern
Triangular infill patterns are sturdy because they are less likely to deform and give the best structural support. Triangles are the strongest shape, according to most 3D fans.
Due of the printhead’s straight-line movement, using a triangular infill also boosts print speed. As a result of their robustness and speed, many 3D enthusiasts choose triangular infills.
Rectangular Infill Pattern
Because of their grid of parallel and perpendicular extrusions, rectangular infills can attain 100% infill density. Due to the print head’s straight-line movement, it has a high print speed, just like the triangular infill.
Hexagonal Infill Pattern
They have the strongest strength-to-weight ratio and tessellated hexagons. Printing is slower than the previous two infill patterns because the printhead is continually changing directions, yet they are excellent in reinforcing 3D prints.
Adjust Flow Rate
Adjusting the flow rate is another good way to make 3D printed things more durable. However, you must be careful not to create under or over extrusion when using this procedure. As a result, most designers ensure that only minor changes are made.
The flow rate can be adjusted for the following:
Flow Against the Wall (Outer Wall Flow & Inner Wall Flow)
To make 3D prints stronger, you can change the flow rate. Most individuals, on the other hand, change the flow rate to remedy other 3D printing concerns including difficulty to obtain volumetric flow and enhance accuracy.
Modify the Line Width
You may reinforce your 3D prints by setting the line width to an even multiple of the layer height, according to Cura, a popular slicer. However, you must exercise caution because this option is linked to extrusion, i.e., a large change in line width can result in excess and under extrusion.
Reduce Cooling
Cooling is a critical step in 3D printing because it impacts the adherence of layers after they have been set. Due to the difficulty of a succeeding layer to bind with another, rapid cooling can limit adhesion. Cooling, on the other hand, is dependent on the substance you’re working with. PLA, for example, performs best when cooled by a powerful fan. As a result, depending on the substance you’re working with, you should slow down the cooling process.
What is the composition of perovskite?
Perovskite is a mineral made up of calcium titanium oxide (CaTiO2) that was discovered by a Russian scientist named Gustav Rose in 1839 and further researched by Russian mineralogist Lev Perovski, hence the name.
What is the process of making solar ink?
A group of Australian scientists from CSIRO (Commonwealth Scientific and Industrial Research Organisation) has been developing printable solar panels in partnership with the Universities of Monash and Melbourne for the past few years. According to the team, they are very close to bringing the new technology to market.
Silicon is used in the majority of solar panels nowadays. The Australian researchers, on the other hand, are working with organic semiconductor polymers, which are subsequently broken down to make ink. The ink that results is capable of capturing light and converting it to power. The ink may be printed on plastic or steel surfaces, which means that the printed solar panels could be integrated into buildings.
From residences to skyscrapers, the technology can be used to generate electricity. The panels can be manufactured in smaller sizes and integrated into electronic accessories to charge phones, tablets, and computers. The experts also claim that connecting the solar panels is a simple and straightforward process.