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facturing process — FASST® reactive transfer processing — for producing monolithically-integrated thin-film modules which have enabled it to be- come a prominent player in the pro- duction of practical and economical solar panels aimed at the fast-grow- ing commercial rooftop and ground- mount solar application markets.


Unique CIGS Process HelioVolt’s CIGS FASST pro -


cess is a two-stage reactive transfer process that separates chemical dep- osition from synthesis. The process relies on chemical reaction between two separate films to form CIGS. These films are brought into close distance and rapidly reacted under pressure in the presence of an elec- trostatic field while heat is applied. The use of two independent thin films provides the benefits of inde- pendent composition and flexible deposition technique optimization, and eliminates pre-reaction prior to the synthesis of CIGS. The separation of the deposition


process from the synthesis step pro- vides the unique ability to control the key parameters required for superior material performance, resulting in the efficient absorption of a broad band of the solar spectrum. The process uses a fraction of the expen- sive semiconductor material utilized in silicon modules. The monolithical- ly-interconnected modules mean no cost-cutting, testing, binning or strin - ging of cells. The modules are true PV integrated circuits (PVICs). Initially developing small-cell,


6-inch PV wafers in 2007, the compa- ny now manufactures 1.2 x 0.6m (4.0 feet x 2.0 feet) full-size CIGS mod- ules with a rating up to 85 watts per panel. HelioVolt’s modules have ex- celled at extensive accelerated envi- ronmental testing, and have been certified by Intertek to UL 1703 and IEC 61646 and IEC 61730 standards. To facilitate the production of its high-quality monolithically-inter-


December, 2014 Solar Thin-Film CIGS Plant


connected CIGS, in 2008 HelioVolt opened a new 125,000 square-foot, 20 megawatt capacity production plant in Austin, Texas. Through every step of the process — from receipt of in- coming flat glass to the two stages of CIGS semiconductor deposition, to the assembly of the final modules and testing, and finally packaging for shipment — the plant is a showpiece for streamlined CIGS manufacturing and throughput. Transporting the CIGS panels


to the production processes through- out the plant, and providing preci- sion infeed and take-away of the glass panels for these systems re- quired an integrated flow of material handling systems to accomplish seamless throughput. To design and implement this material handling system, HelioVolt brought in Shut- tleworth, Inc. Shuttleworth, powered by Pro Mach, Inc., has a long history of providing material handling sys- tems, such as conveyors, accumula- tors and buffers for transporting flat glass, and solar panels, as well as for the transportation of many other electronic components and assem- blies. The company leads the solar industry with providing specialty conveyor systems applicable to ISO Class 6 and for clean environments to ISO Class 3. “The factory line was designed


in collaboration with a number of partners, including Shuttleworth,” says John Prater, Vice President of Business Operations with HelioVolt. “Shuttleworth was a valued partner in creating the line design and the automation schemes that have en- abled us to demonstrate scalability and achieve the performance results like we have seen.” “From the initial receipt of the


flat glass into our plant, it is loaded onto the automated conveyor system,” continues Prater. “As the glass goes though each of our processing steps, through to the end of the line, the con- veyors are transporting the glass pan- els. Our facility has every automated application that Shuttleworth pro- duces for the solar industry.” More than 1,000 linear feet of automated conveyor systems were


Continued on page 38 Contents


Tech-Op-Ed ........................... 4 Tech Watch ........................... 10 People.................................... 12 Business News........................ 14 Business Briefs....................... 15 Management........................ 16 EMS .................................... 18 ElectronicMfg. Prods............. 22 Production.......................... 48 Partnering........................... 50 Distribution........................ 52 New Products....................... 66 High-Tech Events................... 76 Editorial Calendar............... 76 Advertisers Index................... 78


Special Focus: Test and Measurement.......... 54


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