The rapid development of organic-inorganic hybrid perovskite solar cells has resulted in laboratory-scale devices having power conversion efficiencies that are competitive with commercialised technologies. However, hybrid perovskite solar cells are yet to make an impact beyond the research community, with translation to large-area devices fabricated by industry-relevant manufacturing methods remaining a critical challenge. Here we report the first demonstration of hybrid perovskite solar cell modules, comprising serially-interconnected cells, produced entirely using industrial roll-to-roll printing tools under ambient room conditions. As part of this development, costly vacuum-deposited metal electrodes are replaced with printed carbon electrodes. A high-throughput experiment involving the analysis of batches of 1600 cells produced using 20 parameter combinations enabled rapid optimisation over a large parameter space. The optimised roll-to-roll fabricated hybrid perovskite solar cells show power conversion efficiencies of up to 15.5% for individual small-area cells and 11.0% for serially-interconnected cells in large-area modules. Based on the devices produced in this work, a cost of ~0.7 USD W⁻¹ is predicted for a production rate of 1,000,000 m² per year in Australia, with potential for further significant cost reductions.

Metal halide perovskite solar cells (PSC) exhibit outstanding power conversion efficiencies when fabricated as mm-sized devices, but creation of high-performing large-area PSCs that are stable under operating conditions on a sufficiently long timescale still presents a significant challenge. We demonstrate herein that modification of the interface between the perovskite and a spiro-OMeTAD hole-transporting material with commercially available para-substituted benzenethiol molecules facilitates fabrication of cm-sized PSCs with both improved efficiency and stability. Comprehensive analysis using specialised and conventional physical characterisation techniques has been undertaken to demonstrate that band alignment at the perovskite surface can be tuned to improve the solar cell efficiency via adsorption of benzenethiols with a significant dipole moment. Moreover, modification of the perovskite with cyano-substituted benzenethiol enhances charge extraction and reduces charge recombination in the devices. These effects enable improvements in the power conversion efficiency of PSCs from 19.0 to 20.2% and from 18.5 to 19.6% under 1 sun AM 1.5G irradiation with 0.16 and 1.00 cm² apertures, respectively. Most importantly, benzenethiol-modified perovskite solar cells retain more than 80% of the initial performance after 185 h of continuous operation at 50% relative humidity and 50 °C device temperature under 1 sun irradiation, while devices with no interfacial modification undergo continuous deterioration down to 35% of the initial efficiency. These significant improvements are provided by a very simple and highly reproducibile modification procedure that can be readily adopted in other types of PSCs.