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This report summarizes work performed by Solarex, A Business Unit of Amoco/Enron Solar, under this subcontract. Among the accomplishments during the program are the following: Converting all of the production casting stations to increase ingot size, operating them at equivalent yields and cell efficiencies, and thus doubling the casting capacity at a 20% lower cost than the cost of new equipment. Developing a wire-saw process and transferring the process to production; as a result, more than 80% of wafering is now done using wire saws, at higher yields and lower costs than achieved on the internal diameter saws. Developing an aluminum paste back-surface field (BSF) process to increase cell efficiency by 5%; researchers also designed, procured, and transferred to manufacturing a fully automated printing system to produce the BSF cells. Fabricating 15.2-cm by 15.2-cm polycrystalline silicon solar cells and building modules using these cells. Modifying the module assembly area to increase capacity by a factor of three. Implementing a single-layer Tedlar backsheet that reduced backsheet cost by $0.50/ft2. Selecting, testing, and qualifying a low-cost (&lt; $1.00 per module) electrical termination system. Qualifying the structure and adhesive system for mounting frameless modules and using the system to build several large arrays

Cast Polycrystalline Photovoltaic Module Manufacturing Technology Improvements; Final Subcontract Report, 8 December 1993-30 April 1998