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TechWaTch Jan/Feb, 2024


R2R in Industrial Scale-Up: Impacts and Challenges


By Thomas Kolbusch, VP and Director of Sales, Marketing and Technology, Coatema, GmbH T


he Roll-to-Roll (R2R) pro- cessing methodology, piv- otal in the fabrication of


printed electronics, particularly 3rd Gen photovoltaics (OPVs), of- fers significant advantages. Yet, inherent technical challenges pose constraints in achieving op- timal device performance. At its core, R2R involves un-


reeling a flexible substrate from a source, subjecting it to various fabrication processes, and subse- quently reeling the treated sub- strate. These processes can en- compass material deposition, lithographic patterning, and post-fabrication treatments. Benefits include versatility, high through put and economic vi-


ability. Continuous production translates to faster manufactur- ing cycles. Economies of scale achieved reduce per-unit costs. It enables the creation of light- weight, flexible electronic devices.


Uniformity Attaining uniformity in dep-


osition across vast substrate lengths poses a formidable chal- lenge. Factors such as deposition rate, substrate tension, and am- bient temperature influence the end product’s quality. For OPVs, the choice of mate-


rials is critical. Many organic ma- terials used in these cells are sen- sitive to environmental factors like humidity and temperature.


The R2R process, being continu- ous, requires that these materials remain stable over extended peri-


Attaining uniformity in deposition across vast substrate lengths poses a formidable challenge. Fac- tors such as deposition rate, substrate tension, and ambi- ent temperature influence the end product’s quality.


ods, a challenge that is currently under intensive research. Securing uniform device ef-


ficiency across an extended sub- strate requires rigorous quality control. Discrepancies in layer composition or thickness can cul- minate in efficiency variations, detracting from the overall process yield. Over the last 20 years, signif-


icant strides have been made in OPV technology. These include material evolution, architectural refinements and optimization of R2R processes. Novel organic compounds have been introduced that enhance light absorption and electron mobility. Tandem struc- tures, where multiple OPV layers are stacked, have emerged to en- hance the cell’s absorption spec- trum. Advancements in substrate control, improved coating and printing techniques, and swifter post-deposition treatments have been established. Despite these advance-


ments, the conversion efficiency of R2R-produced OPVs remains an area of ongoing research when compared to other photo- voltaic technologies.


Clear Potential The potential of the R2R


DL Technology has been the leader in micro dispensing technology for over 15 years. For more 


www.dltechnology.com 216 River Street, Haverhill, MA 01832 • P: 978.374.6451 • F: 978.372.4889 • sales@dltechnology.com


process in reshaping printed electronics production is clear. However, its broader adoption, especially for OPVs, demands a precise understanding of its chal- lenges and a continuous drive for research and innovation. The ad- vancements over the past 20 years underline the ongoing ef- fort in this field and the need for further refinement to fully ex- ploit R2R’s benefits in OPV man- ufacturing. Coatema is working on all of these topics with cooper- ation partners in R&D and in- dustry and with the Horizon Eu- rope project Flex2Energy will es-


tablish a production line for OPV in Greece with integrated mod- ule assembly. This will be a boost to the European efforts to be more independent from imports


from China. Contact: Coatema GmbH,


Roseller Strasse 4, 41539 Dormagen, Germany % +49-2133-97840 E-mail: tkolbusch@coatema.de Web: www.coatema.de r


Emerald EMS to Exhibit at IME West


SALEM, NH — Emerald EMS is exhibiting at IME West 2024. Renowned for its commitment to driving innovation in design, en- gineering and manufacturing, the company stands at the fore- front of progress in the life sci- ences technology sector. At Booth 3197, the Emerald


EMS team will showcase its ex- pertise as a trusted partner for OEM and life sciences suppliers. The company specializes in the development of cutting edge technologies, including machine learning, robotics, disruptive dig- ital health device design, and in- novative materials. Emerald EMS’ state of the


art manufacturing equipment en- ables the delivery of a comprehen- sive range of services, including electromechanical and system as- sembly, precision touch ups, in- circuit and functional testing, re- work and complex repair services, final testing, integration, box builds, order configuration, and direct order fulfillment. The company’s capabilities al-


so encompass sophisticated SMT placement and cleanroom assem - bly, showing its ability to meet di- verse manufacturing needs. Its ISO-13485-certified and


FDA-registered U.S. manufactur- ing facilities are recognized for their excellence, providing elec- tronic manufacturing services tai- lored to high-reliability life science


and patient safety applications. Contact: Emerald EMS, One


Stiles Road, Salem, NH 03079 % 408-385-7761 E-mail: monica.guzman@emeraldems.co m Web: www.emeraldems.com


See at IME West, Booth 3197


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