Spray coating is a promising way to deposit perovskite solar-cell films at larger scale, but it has not yet been shown to deliver commercially proven spray-deposited modules. Research reports strong cell efficiencies and progress toward continuous processing; uniform films, controlled drying and crystallization, durability, and validated module performance remain open commercialization tests.
How spray deposition works—and why it could scale
Spray deposition applies a liquid precursor solution to a substrate as droplets. As the solvent dries, the deposited material forms a perovskite film. The approach is attractive because coating can potentially be adapted to large substrates and continuous production lines, rather than relying only on small, individually processed laboratory devices.
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That potential depends on controlling several linked variables: droplet size and overlap, ink composition, substrate temperature, drying time, and the spray path across the substrate. If a later pass re-dissolves film that has already formed, or if droplets dry unevenly, the finished layer can become inconsistent. Overspray can also contaminate nearby areas or equipment. A 2024 review identifies these as important process and scale-up challenges, not details that disappear simply by increasing the coating area. Light: Science & Applications, 2024
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Published performance figures indicate laboratory progress, but they describe different devices and measurements. A cell’s peak efficiency is not interchangeable with stabilized output, and a cell result does not establish the performance of a module.
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| Evidence | Reported result | What it establishes |
|---|---|---|
| Spray-coating literature surveyed by a 2024 review | 24.31% reported as the highest power-conversion efficiency achieved using a spray-coating method in the literature reviewed; the review also reports a largest spray-coated active area of 112 cm². | A review-reported literature benchmark. It is not evidence that a commercial module has achieved that efficiency or area. |
| One-step spray-coated, methylammonium-free cells, reported in 2024 | 21.0% peak efficiency and 19.4% stabilized efficiency. | Two measurements for a specific cell study; the stabilized value should not be presented as the peak value or generalized to all spray-coated cells. |
| Fully spray-cast cells reported in a 2020 paper | 19.4% efficiency. | Historical evidence of the method’s potential, not a current record. |
The 24.31% and 112 cm² figures are reported by the authors of the 2024 review, while the 21.0% peak and 19.4% stabilized results come from a separate study. Because device structure, area, and measurement type differ, these numbers should not be read as a like-for-like ranking. 2024 review; Solar RRL study, 2024; ACS Applied Materials & Interfaces study, 2020
What has—and has not—been demonstrated for continuous production
A 2024 Solar RRL study reports a spray-coated surface-passivation approach designed to be compatible with high-throughput roll-to-roll processing. That is relevant manufacturing progress, but compatibility of a treatment with a continuous line is not the same as demonstrating a mass-produced spray-coated module.
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Separately, a 2024 Nature Communications paper demonstrated perovskite modules fabricated entirely by roll-to-roll processing under ambient room conditions. This shows that continuous module manufacturing has been demonstrated using the processes in that study. It does not show that the modules were made by spray deposition, so the result should not be attributed to spray coating. Solar RRL study, 2024; Nature Communications study, 2024
What the stability results mean
A 2025 RSC Sustainability study tested perovskite cells with a spray-coated polystyrene layer. The authors reported 80% efficiency retention after 40 hours immersed in water or after 40 hours at 95 °C. These are results from specific laboratory stress tests; they do not establish outdoor service life, performance under a range of weather conditions, or commercial module qualification. RSC Sustainability study, 2025
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What would make spray deposition commercially credible?
Commercialization requires more than a high-performing small cell or a coating step that could fit a production line. The evidence needs to connect process control to repeatable, durable module output.
- Uniformity across the full area: demonstrate consistent films and device performance across module-sized substrates, not only a small active region.
- A robust process window: show that droplet behavior, ink formulation, temperature, drying, and spray trajectory remain controlled at production-relevant speeds and widths.
- Module-level results: report module efficiency and area separately from cell efficiency and active area, with transparent measurement methods.
- Meaningful stability protocols: provide conditions, duration, encapsulation details, and retained performance in tests relevant to module use.
- Repeatable manufacturing evidence: establish that results can be reproduced across runs and integrated into a continuous process, rather than relying on a single laboratory demonstration.
The reviewed literature reports spray-coating milestones and a compatible passivation approach, while separate work demonstrates roll-to-roll perovskite modules. Those are meaningful steps, but together they do not establish qualified, commercially manufactured spray-deposited modules. Light: Science & Applications review, 2024; Solar RRL study, 2024; Nature Communications study, 2024
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