Laser-Assisted Microfluidics Technology for Additive Manufacturing

Abstract

Researchers at the University of Central Florida have invented a novel additive manufacturing system and methods for thin film fabrication specifically useful in fabricating higher performance solar photovoltaic (PV) cells at a fraction of the cost of traditional PV cell manufacturing methods. Today's commercial solar cells are expensive to produce ($100-$400 per m²) and typically have low conversion efficiency (15-20 percent). With the new Laser-Assisted Manufacturing Process Using Microfluidic Suspensions and Dry Powders, companies can make next-generation PVs, such as Intermediate Band Solar Cells (IBSCs), for far less (approximately $30 per m²). More importantly, IBSCs have high conversion efficiency (~50 percent).

Technical Details

The invention comprises a system and methods of fabricating additively manufactured structures using a roll-to-roll process technology and a unique and novel laser electrospray printhead. The inventive concept accommodates scalable large structures, wherein cylinders (feed and take-up spools) move or roll a substrate through an electrospray module. The module deposits microdroplets of nanoparticles onto the substrate through both hydrodynamic and electrodynamic shear. The electrospray module can operate in a steady cone-jet spray mode and a micro-dripping mode, depending on the manufacturing requirements. As the substrate moves, an annular laser beam dries and sinters the wet nanoparticles, fusing them onto the substrate one layer at a time. To focus the laser beam, the system uses either a hollow parabolic mirror or a hollow flat mirror and an annular lens, as required. The same concept can produce regular arrays of microdots and nanodots.

Benefit

Market Application