Martin Hermenau | Heliatek: How do flexible, lightweight PV modules overcome the inherent temperature sensitivity of traditional silicon, especially in building-integrated applications?

What advanced manufacturing and quality assurance protocols are essential for scaling flexible organic photovoltaics from pilot to mass production?

The transition from pilot-scale development to mass production for flexible PV modules necessitates robust manufacturing infrastructure and sophisticated process control. Our production facility, operational since 2018, employs a roll-to-roll manufacturing approach, processing PET films up to 1.3 meters wide and 5.2 kilometers in length. This continuous process integrates multiple steps, including bare handling, precision cutting, lamination, and highly accurate laser processing, all underpinned by extensive process know-how developed over more than a decade.

Maintaining product quality and consistency at scale is paramount, achieved through a comprehensive quality management system. The facility is ISO 9001 certified and undergoes regular factory audits by third-party organizations like TÜV to ensure continuous compliance with IEC and UL certification standards. A sophisticated Manufacturing Execution System (MES) tracks every module from the initial process step, recording material batches, process conditions, and all inspection data, including IV curves and electroluminescence images, to ensure full traceability and consistent product parameters.

In this short video, you can learn:
* The scale and methodology of roll-to-roll production for flexible PV.
* Key process steps and technical expertise required for flexible module manufacturing.
* The quality assurance framework, including certifications and data traceability systems.

📋 **Clip Abstract** This segment outlines the advanced roll-to-roll manufacturing processes and stringent quality control measures employed for flexible PV modules. It emphasizes the importance of deep process know-how and comprehensive data tracking for mass production.

What critical material and architectural innovations were required to achieve IEC 61215 certification for organic photovoltaic modules, a benchmark notoriously difficult for flexible technologies?

Achieving international certifications, particularly IEC 61215, for organic photovoltaic (OPV) modules has historically presented significant technical challenges, requiring a decade of dedicated research and development. This standard, which mandates rigorous durability and performance testing, proved particularly difficult for early OPV technologies due to their inherent sensitivity to environmental degradation. Success was ultimately contingent upon two critical breakthroughs: one in the solar cell stack architecture and another in the barrier system design, which collectively enhanced the module's resilience against environmental stressors.

The successful certification across multiple product generations and power classes, including IEC 61730 and UL standards for the American market, underscores the maturity and reliability of the technology. Beyond these core PV standards, modules have also achieved specialized certifications for salt corrosion and ammonia resistance, essential for market access in regions like Dubai. These repeated certifications, validated through regular factory inspections, confirm the consistent production of modules that meet stringent global performance and durability requirements.

In this short video, you can learn:
* The historical challenges in certifying organic photovoltaic modules to IEC standards.
* The specific technical advancements in cell stack and barrier systems that enabled certification.
* The range of international certifications achieved, including specialized environmental resistance tests.

📋 **Clip Abstract** This segment details the arduous journey and technical innovations required to achieve critical IEC certifications for organic photovoltaic modules. It highlights the breakthroughs in cell stack and barrier technology that enabled the modules to meet stringent durability standards.