As PV cell designs become more advanced, manufacturers face growing demands for precision, throughput and production consistency. Laser processing plays a key role in critical steps, from metallisation and xBC patterning to selective PN-junction removal, edge passivation and cell cutting. ATW (Wuxi Autowell Technology Co., Ltd.) provides equipment for these applications, combining precise laser processing, high throughput, cell-breakage control and production-line integration to support stable manufacturing of advanced PV cells.
The Role of Laser Processing in PV Manufacturing
New cell architectures bring new manufacturing challenges. Manufacturers must control processing quality, handle different cell sizes and maintain consistent output at production scale. Achieving these goals depends on both cell design and the equipment used to manufacture it.
Laser processing offers a way to address these challenges. It enables targeted material processing across several stages of cell production. Each application has its own requirements. Metallisation calls for speed and flexibility. xBC patterning demands precise processing and good edge quality. Selective PN-junction removal and edge passivation require control over the processed area. Cell cutting must deliver consistent dimensions while limiting breakage.
Equipment must also work as part of a wider production system. High processing speed alone is not enough. Manufacturers need reliable handling, effective inspection and smooth integration with neighbouring processes.
ATW’s PV equipment portfolio covers these key stages. Each solution is designed around the demands of its application, with a focus on processing quality, throughput and production-line compatibility.
Equipment Solutions for Key Manufacturing Processes
Laser-Assisted Sintering (LEM): Flexible, High-Efficiency Solutions Across Cell Designs
ATW offers a comprehensive portfolio of laser-enhanced metallisation (LEM) equipment, featuring an industry-first integration of primary and secondary sintering processes. Designed for diverse cell architectures, the solutions support SMBB, 0BB, and dedicated back-contact (BC) configurations, with both area-scan and line-scan processing modes available. Their modular architecture also enables seamless integration with passivation equipment and inspection systems.
High throughput and production stability are central to the equipment design. Supporting cell sizes from 182 mm to 230 mm, the systems achieve cycle times of ≤0.65 s and throughput of up to 9,500 UPH. An industry-first dual-cell simultaneous loading and unloading system, combined with mid-cell pressurisation, reduces beat time by 50% compared with conventional single-cell handling. The equipment maintains a cell breakage rate of ≤0.01%, supporting stable, high-volume production.
Efficiency gains are delivered through both primary and secondary LEM processes. Primary LEM achieves an efficiency improvement of >0.3%, while secondary LEM provides an additional gain of 0.05%. For TOPCon cells, the combined efficiency improvement reaches ≥0.35%, based on BSL. Validated in mass production by leading industry manufacturers, with cumulative equipment installations approaching 40 GW, ATW’s mature multi-spot processing technology also supports retrofitting existing production lines, offering manufacturers a practical route to efficiency improvement while controlling investment costs.
xBC Laser Patterning: Precision and Heat Control
Back-contact cell designs require precise patterning to form the intended electrode regions. For xBC cells, edge quality and control of the heat-affected zone (HAZ) are key process considerations. Manufacturers must achieve the required pattern quality while maintaining throughput and supporting automated material handling.
ATW’s xBC laser patterning equipment uses a UV picosecond laser optical system and a shaped-beam design. These features support precise pattern opening and help control thermal effects. The equipment also supports carrier loading and automated guided vehicle (AGV) docking, making it easier to connect the process with automated production lines.
For 210R cells, the specified throughput is at least 4,000 cells per hour. The equipment supports cell sizes from 182 mm to 230 mm and thicknesses from 110 μm to 180 μm. Specified edge-jaggedness is no more than 10 μm, and the HAZ is no more than 10 μm.
These capabilities address key xBC manufacturing needs: pattern quality, edge consistency, thermal control and automated handling. Results depend on the cell design, pattern geometry, materials and process settings, and should be validated under the intended production conditions.
Selective PN-Junction Removal and Passivation: Meeting the Needs of Multi-Cut Cells
As photovoltaic cell designs evolve towards half-cut and multi-cut formats, including three-piece and four-piece configurations, cut-edge processing becomes increasingly important. Cell segmentation can create parasitic shunt paths and increase edge recombination, potentially reducing electrical performance. Manufacturers must therefore control edge-related losses while maintaining low cell-breakage rates, high throughput and reliable equipment operation.
ATW’s laser processing solution selectively removes the PN junction along the cut edge, forming an electrically isolating region that helps suppress parasitic shunting and reduce edge leakage current. When combined with subsequent ALD side-edge passivation, the process can also help mitigate surface recombination. By addressing these distinct edge-related loss mechanisms, the two processes offer complementary approaches to preserving cell performance and improving power output.
ATW’s solution supports different process strategies according to cell architecture, segmentation format and investment priorities.
Component power gain of ≥2 W: Selective laser PN-junction removal alone can deliver a component power gain of ≥2 W under the specified process conditions.
An alternative for half-cut cells: The laser process is already in mass production. ALD side-edge passivation can deliver an average component power gain of more than 6 W, while requiring a higher initial capital investment. Laser PN-junction removal offers an alternative for manufacturers seeking edge-loss control with lower upfront investment.
Flexible integration for multi-cut cells: For three-piece and four-piece formats, laser PN-junction removal can be implemented independently or combined with ALD side-edge passivation. The combined approach addresses both parasitic shunting and surface recombination, with the overall benefit depending on cell architecture and process conditions.
These capabilities help manufacturers balance edge-processing quality, production throughput and equipment availability. The appropriate configuration depends on cell architecture, segmentation format, processing position and downstream process requirements. Validation under actual production conditions is essential to establish the achievable efficiency gains and confirm compatibility with the wider manufacturing line.
Laser Cell Cutting: Throughput with Integrated Inspection
Cell cutting prepares cells for module assembly. The process must deliver consistent dimensions while limiting breakage. Inspection is also important: cracks, edge chipping and cutting defects need to be identified before cells move to the next stage.
ATW’s PV cell laser cutting equipment uses a dual-track configuration and supports inspection before and after cutting. Pre-cut inspection can cover corner and edge chipping, cracks, cell orientation, photoluminescence (PL) and microcracks. Post-cut inspection can identify cutting or splitting failures, cracks, chipping and strip-width variation.
This combination of cutting and inspection helps manufacturers monitor cell quality throughout the process. Inspection coverage and acceptance criteria can be tailored to production and quality-control requirements.
In dual-track configuration, the equipment has a specified throughput of at least 11,000 full cells per hour in online operation and at least 14,000 full cells per hour in offline operation. It supports cell sizes from 156 mm to 230 mm and thicknesses from 110 μm to 180 μm. The specified cell-breakage rate is no more than 0.03%. Equipment uptime is at least 99.5%, and cutting accuracy for strips of unequal width is ±0.1 mm.
These specifications help manufacturers assess the equipment’s suitability for their throughput and quality targets. Actual results depend on operating conditions, equipment configuration and inspection criteria.
Integrating Equipment into the Production Line
Machine specifications are only part of the picture. Actual production output also depends on loading, unloading, inspection, material handling and the cycle times of upstream and downstream processes. Processing quality must be assessed under defined operating conditions and against agreed inspection methods.
Three factors deserve particular attention when selecting laser equipment.
Process fit. Different cell designs and manufacturing steps require different levels of precision and thermal control. Equipment should be selected according to the target process and cell architecture.
Line integration. A machine must work at a pace that fits the surrounding production line. Material-transfer systems, automation interfaces and inspection processes all affect overall performance. A machine’s rated throughput does not necessarily reflect the output of the complete line.
Quality validation. Cell-breakage rate, edge quality, cutting accuracy and equipment uptime should be measured under agreed test conditions. For new installations or line upgrades, manufacturers should define equipment configuration, process windows, test methods and acceptance criteria before deployment.
ATW’s equipment solutions address different process requirements across PV cell manufacturing. Their suitability depends on the target application and the needs of the production line. Testing under actual operating conditions remains essential to confirm performance.
Supporting Advanced PV Cell Manufacturing
Laser processing serves several important functions in PV cell production. It supports metallisation, pattern opening, selective PN-junction removal, edge passivation and cell cutting. As cell designs evolve, manufacturers must balance processing precision with throughput, product compatibility and automation.
ATW offers equipment solutions for these critical manufacturing stages. By addressing specific process requirements and supporting production-line integration, its equipment gives manufacturers options for implementing different cell designs and production strategies.
The key is to match equipment capabilities to the intended process. Clear performance targets and validation under defined production conditions help manufacturers assess how a laser-processing system will perform in their own manufacturing environment.
About ATW
ATW supplies intelligent manufacturing equipment for the photovoltaic, lithium battery and semiconductor industries. Its PV portfolio covers equipment for cell and module manufacturing, with solutions addressing different production stages. The company focuses on matching equipment design to process requirements, including precision, throughput, yield control and production-line integration. Its PV equipment supports applications such as laser-enhanced metallisation, xBC laser patterning, selective PN-junction removal and passivation, and laser cell cutting, helping manufacturers implement advanced cell designs in volume production.
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