Industrial Implementation of Heterojunction Solar Cell Technology Transfer from Pilot Line to One-Gigawatt Production

Abstract

Heterojunction (HJT) silicon solar cell technology has long been recognized for its high open-circuit voltage potential, but the path from pilot-line demonstration to one-gigawatt mass production presents substantial industrialization challenges. This case study documents a successful technology transfer covering equipment qualification for amorphous silicon plasma-enhanced chemical vapor deposition, transparent conductive oxide sputter-deposition uniformity, low-temperature silver-paste metallization, and end-of-line classification. We discuss the resolution of three unanticipated yield-loss mechanisms encountered during ramp-up: edge-passivation discontinuity, interfacial fluorine contamination from upstream texturing, and busbar-paste fingertip lift during low-temperature firing. The narrative provides a reference template for organizations contemplating similar industrial transitions and quantifies the typical time-and-cost envelopes associated with each ramp-up phase.