Solar Cell Design for Manufacturing

GE Energy is commercializing a process for directionally solidifying individual molded wafers. The process has demonstrated good material utilization and very low cost, both in terms of capital equipment expense and direct material consumption. A new molded wafer furnace will be put into operation in the first quarter of 2007. Modules based on molded wafer solar cells will be marketed in the second half of 2007. 1. Objectives The broad objectives of this DOE Photovoltaic Manufacturing R&D Program are to implement critical improvements to the process of casting individual wafers. Those improvements will lead to a novel all back interconnected module technology. The product is being developed following GE’s Design for Six Sigma approach to deliver a product ready for largescale manufacturing. Coupled with improvements in wafer quality, this program will result in modules with costs 30% lower than the industry standard cast multicrystalline wafer based products. 2. Technical Approach