Swansea University and University of Antioquia Use Roll-to-Roll Coater for Perovskite Coating and Inspection With 98% Thickness Accuracy

In a new study, researchers from the University of Antioquia and Swansea University used an infinityPV Laboratory Roll-to-Roll Coater to develop a new method for real-time, non-destructive thickness monitoring of perovskite films.

Perovskite solar cells (PSCs) are a promising alternative to traditional photovoltaics due to their high efficiency and low production costs. However, scaling up their manufacturing presents challenges, particularly in ensuring the uniformity of thin films, which directly impacts device performance. Traditional quality control methods, such as profilometry, are destructive and impractical for in-line inspections, making them unsuitable for continuous production environments.

To address this, the research team integrated a machine vision-based profilometry tool with the Laboratory Roll-to-Roll Coater.

By combining transmitted-light imaging with a deep-learning model, they achieved highly accurate, real-time thickness measurements of perovskite films. The system matched the precision of traditional methods, enabling automated quality control for scalable production.

What You Need to Know

• Researchers used a Laboratory Roll-to-Roll Coater to produce perovskite films and integrated a camera system to measure their thickness in real time without damaging the material.

• The system achieved 98.5–98.6% accuracy in predicting film thickness, comparable to traditional profilometry. The method was successfully tested in a continuous roll-to-roll production environment, proving its scalability.

• This approach can be extended to other thin-film technologies, making it a versatile solution for advanced manufacturing.

The Laboratory Roll-to-Roll Coater was used to fabricate flexible perovskite solar cells.

How the Laboratory Roll-to-Roll Coater Was Used

The Laboratory Roll-to-Roll Coater played a key role in both producing perovskite films and enabling real-time thickness monitoring.

The researchers integrated a camera system into the coater to capture images of the films during production. These images were then analyzed to generate detailed thickness maps, providing immediate feedback on film uniformity.

This setup allowed for continuous in-line monitoring, ensuring consistent quality throughout the manufacturing process. By combining production and inspection, the system demonstrated how the coater can be used for smarter, more efficient thin-film manufacturing.

“For the continuous slot-die deposition experiment an infinityPV R2R equipment was used (LR2RC750) at CIDEMAT group at the University of Antioquia. A MAPbI3 perovskite ink (20% wt, acetonitrile/methylamine) was slot-die coated over PET/ITO substrates previously cleaned using Isopropanol. No further treatment was done to the substrate. A web speed of 0.3 m/min, a gap of 150 μm using a shim thickness of 150 μm, and a pump rate of 0.3 mL/min were used for the continuous slot-die coating process. A “nitrogen knife”system was placed right after the slot-die head to control the drying process of the films. Once the perovskite films were deposited, annealing was carried out by placing a hot plate set to 100◦C beneath the tensioned substrate. The annealing process lasted for 10 min under 30%–40% relative humidity.”

— Direct Quote from the Research Article

What This Means for Your Research

This study highlights the transformative potential of integrating a Laboratory Roll-to-Roll Coater with machine vision and AI for thin-film manufacturing. For researchers and industries working with perovskite solar cells or similar technologies, this approach offers a cost-effective and non-destructive alternative to traditional quality control methods. The ability to monitor film thickness in real time allows for immediate adjustments to coating parameters, improving yield and reproducibility.

By adopting this method, researchers can bridge the gap between lab-scale efficiency and large-area production, gaining a competitive edge in high-throughput, defect-free manufacturing.

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Peer-Reviewed Studies Featuring the Laboratory Roll-to-Roll Coater