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Spray deposition is a promising way to make perovskite solar-cell films over larger areas, but it has not yet been shown to produce commercially qualified, mass-produced modules. Published studies report strong cell efficiencies and progress toward continuous processing; they do not establish commercial-scale spray-deposited panels. The distinction matters: a laboratory cell result, a stabilized efficiency, a large active area, and a finished module are different kinds of evidence.
How spray deposition forms a perovskite film
Spray coating applies a liquid precursor as droplets across a substrate. As the solvent evaporates, the material crystallizes into a thin film that becomes part of the solar cell. Compared with methods that coat only small areas, spraying may offer a path to larger substrates and continuous production.
The outcome depends on several interacting settings, not simply whether a sprayer can cover a surface. A review of perovskite industrialization identifies droplet size, ink composition, substrate temperature, drying time, and spray trajectory as important controls. Droplets arriving on a partly formed film can re-dissolve it, while overspray can contaminate nearby areas or the production environment. These factors make uniformity and a repeatable process window central scale-up challenges. Light: Science & Applications, 2024
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What efficiency results have spray-coated cells achieved?
Reported percentages are useful only with their measurement context. Peak and stabilized cell efficiencies are not interchangeable, and neither number by itself describes a module’s output or commercial readiness.
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| Evidence | Reported result | What it establishes |
|---|---|---|
| Review of spray-coating literature, 2024 | 24.31% highest power-conversion efficiency reported in the surveyed literature; largest spray-coated active area reported was 112 cm² | A review-reported literature benchmark for spray-coated devices, not proof of a commercially qualified module |
| One-step spray-coated methylammonium-free cells, Solar RRL, 2024 | 21.0% peak efficiency and 19.4% stabilized efficiency | Cell performance in that study; the authors also reported a spray-coated passivation approach compatible with high-throughput roll-to-roll processing |
| Fully spray-cast cells, 2020 review | 19.4% efficiency | Historical evidence of the method’s potential, not a current record |
The 24.31% and 112 cm² figures come from a 2024 review’s survey of published work, whereas the 21.0% peak and 19.4% stabilized values come from one 2024 study with a particular cell design. They should not be treated as a head-to-head ranking: device architecture, active area, measurement type, and study conditions differ. The review also describes crystallization control and film uniformity as ongoing challenges. Light: Science & Applications review; Solar RRL study; ACS Applied Materials & Interfaces review
How far has spray coating progressed toward manufacturing?
The strongest manufacturing case is that spray deposition is compatible in principle with scaling and that specific process steps have been designed for continuous lines. In the 2024 Solar RRL study, the authors reported a spray-coated surface-passivation approach compatible with high-throughput roll-to-roll processing. That is evidence of process compatibility for the passivation step, not evidence that complete spray-deposited modules are already being mass-produced.
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For a commercial claim, the key distinction is between a scalable idea and a validated production product. The available studies establish laboratory progress and relevant manufacturing concepts; they do not demonstrate qualified, mass-produced spray-deposited modules. Reviews of large-area fabrication discuss the broader process challenges, but large-area research is not by itself proof of commercial output. Light: Science & Applications, 2024; Energy & Environmental Science, 2025
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What stability evidence says—and does not say
A 2025 RSC Sustainability study reported that perovskite cells spray-coated with polystyrene retained 80% of their efficiency after 40 hours immersed in water or after 40 hours at 95 °C. These are results from specific laboratory stress tests, not measures of outdoor operating life. They do not establish performance over years, module qualification, or bankability. RSC Sustainability, 2025
When comparing stability claims, check the test environment and duration, whether the tested device was a cell or module, and whether encapsulation was used. A short exposure test can indicate how a particular treatment responds to that stress; it cannot substitute for evidence under real-world operating conditions.
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What would demonstrate commercial readiness?
A persuasive commercialization case would need more than a high cell-efficiency figure. Readers assessing future claims should look for evidence across these dimensions:
- Device format and area: whether results are for small cells, larger-area devices, or complete modules, and the active area tested.
- Efficiency measurement: whether the value is peak or stabilized, with enough context to compare like with like.
- Uniformity and process control: whether the coating remains consistent across the substrate and over repeated production runs, despite coupled droplet, ink, temperature, drying, and trajectory variables.
- Production evidence: whether the process has run continuously at relevant throughput, rather than only showing that one coating step could fit a roll-to-roll line.
- Durability: whether testing covers appropriate environmental conditions and duration for the intended application, and whether module-level qualification is reported.
Until those links are demonstrated together for spray-deposited modules, cell records and continuous-manufacturing demonstrations should be read as progress toward scale—not as evidence that commercial spray-coated panels are established.
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