Open Access Article
Inma
Gomar-Fernández
,
Lidón
Gil-Escrig
*,
Nathan
Rodkey
,
Federico
Ventosinos
,
Maximiliano
Senno
,
Cristina
Roldán-Carmona
,
Vladimir
Held
,
Michele
Sessolo
and
Henk J.
Bolink
*
Instituto de Ciencia Molecular, Universidad de Valencia, C/Catedrático J. Beltrán 2, 46980 Paterna, Spain. E-mail: lidon.gil@uv.es; henk.bolink@uv.es
First published on 4th October 2025
Perovskite solar cells (PSCs) exhibit remarkable efficiency and versatility in fabrication methods. In this work, we present methylammonium lead iodide (MAPI) perovskite films deposited using a large-area close-space sublimation (CSS) technique. The large-area CSS system used here enables the simultaneous conversion of multiple samples under moderate vacuum conditions (1 mbar), offering a scalable and simple alternative to other high-vacuum techniques. The perovskite films have large grains and uniformly cover the substrate. These CSS prepared films lead to solar cells with a power conversion efficiency (PCE) of 18.8%. The solar cells have extraordinary stability, and they retain 90% of their initial efficiency after operating for 1000 hours at their maximum power point at 75 °C and under 1 sun illumination. The results highlight the potential of CSS as a scalable and simple method to produce high-quality perovskite films.
Broader contextThe rapid rise of perovskite solar cells places them at the forefront of next-generation photovoltaics, yet scalable and reliable manufacturing routes remain a critical bottleneck. Solution processing dominates academic research, while industrial thin-film technologies are largely based on vacuum deposition. Close-space sublimation (CSS), a mature technique in chalcogenide semiconductors, offers an attractive solvent-free and high-throughput pathway, but its potential for large-area and stable perovskite devices has been scarcely explored. Here we show that CSS operated under mild vacuum enables reproducible fabrication of uniform, large-grain perovskite films across multiple substrates simultaneously, delivering nearly 19% power conversion efficiency and excellent operational stability under continuous stress. By combining simplicity, scalability, and stability, CSS establishes itself as a strong candidate for industrial adoption, bringing perovskite photovoltaics closer to commercial reality. |
Solution-based methods are the most widely adopted, and account for the majority of the research leading to the highest PCEs in the field.15–19 Recently, solar cells employing vacuum-processed perovskite films have also surpassed the 26% threshold.20 Vacuum processing relies on the thermal evaporation of the solid precursors, which can be carried out simultaneously with co-evaporation, but also sequentially, in a two-step approach. In sequential deposition methods, inorganic precursors are deposited first via thermal evaporation and are then converted to the perovskite by applying the organic precursor(s) in a second sublimation step.21,22 In hybrid methods, organic precursors are applied onto a vacuum deposited inorganic film via a solution-based technique, or vice versa.11 Dry vacuum processing offers advantages for industrial-scale fabrication, including the elimination of solvents, precise control over perovskite film thickness and composition, and the capability to construct multilayer architectures.23,24 However, even in recent reports of fast thermal deposition, it is a rather slow process.23,25,26 In co-sublimation, compositional control is challenging, in particular for multi-cation and -anion perovskites as the sublimation rates of all precursors must be controlled simultaneously.27–30 In sequential or two-step methods, usually, only the inorganic components are co-sublimed, allowing for an easier control of the composition as they have more stable evaporation rates.
Close-space sublimation (CSS) is an industrial method to prepare thin-film semiconductors.31 In CSS, the substrate is placed in close proximity to the source. As the distance that the vapour needs to overcome is small, it can operate at moderate vacuum levels.32 When CSS is applied for the fabrication of perovskite films, the inorganic precursor layer is converted to perovskite by placing it in close proximity (typically 1–2 mm) to the organic precursor. The CSS technique has been employed for perovskite deposition, offering a promising route for scalable fabrication. In some studies, configurations classified as CSS have been implemented where the organic source is not recovered during the process, which may pose certain limitations regarding material utilization and long-term sustainability.33–36 Nevertheless, other approaches have demonstrated the feasibility of the CSS technique in which the organic source is reusable, contributing to more resource-efficient and potentially cost-effective processing.37–39 Recently, using a custom-made small-area CSS system with individually controlled source and substrate heaters, our group demonstrated the fabrication of an efficient fully evaporated n–i–p perovskite solar cell.40 This was achieved using a reusable source of the organic perovskite precursor salt, formamidinium iodide (FAI), where the FAI powder was compressed into a pellet. In this study, a large area (96 cm2) CSS tool has been used to prepare methylammonium lead iodide (MAPI) perovskites. This allows simultaneous deposition of the perovskite on six 3 by 3 cm substrates with high spatial uniformity. When integrated into thin-film solar cells, these films yielded devices with minimal performance variation per substrate. Using this method, we achieved p–i–n perovskite solar cells with a power conversion efficiency (PCE) of 18.8% and remarkable stability; they retain 90% of their initial efficiency after operating for 1000 hours at their maximum power point at 75 °C and under 1 sun illumination.
We employed fluorine tin oxide (FTO) coated glass substrates for the conversion process. Prior to the thermal sublimation of the 200 nm PbI2 inorganic scaffold, a thin film (1.5 nm) of (2-(3,6-dimethoxy-9H-carbazol-9-yl)ethyl)phosphonic acid (MeO-2PACz) was deposited on the FTO substrate, acting as the hole transport layer (HTL). Both MeO-2PACz and PbI2 were sublimed in dedicated high vacuum chambers integrated in inert gloveboxes.41 The next step involves the conversion of PbI2 to MAPI within the CSS tool by subliming MAI, according to the schematic process shown in Fig. 1b. The source and substrate are heated to the targeted temperature, and the conversion starts when the pressure is reduced from atmospheric pressure to 1 mbar. This conversion process ceases upon restoring the pressure to atmospheric levels. This method allows for precise control of the conversion time in the CSS system. Fig. 1c illustrates the visual transformation of the films, transitioning from the characteristic yellowish colour of the PbI2 layer to the dark-brown-colour of the MAPI perovskite film, a first indication that the conversion has taken place. Since all the substrates exhibit a uniform dark coloration as observed in Fig. 1d, it appears that the temperature is uniform across the bottom and top plates. This implies that large area substrates can be used, or, as in our case multiple substrates can be converted simultaneously.
In CSS, multiple parameters influence the conversion process. These include the gap between the source and the substrate, their temperatures, the thickness and composition of the inorganic layer, as well as the type of the source material. Using a gap of 1.4 mm and a working pressure of 1 mbar, we varied the source temperature (Tsource) to evaluate the effect on the perovskite growth. In particular, Tsource of 80, 90 and 100 °C were evaluated using 30 min conversion time. The X-ray diffraction (XRD) patterns of the resulting perovskite films are displayed in Fig. S4 of the SI. Insufficient source and substrate temperature results in an excess of MAI content and almost no appearance of the perovskite diffraction peaks. The optimal conditions for the perovskite formation were found when the source was heated to 100 °C.
To shorten the processing time, Tsource can be increased to 120 °C, so that the perovskite formation is completed after 5 min conversion, see Fig. S5. Even though these short conversion times are one of the benefits of CSS for perovskites, it does make reproducibility in this batch process more challenging. Shorter times, imply that the start and end of the deposition of the MAI need to be well controlled as this determines the stoichiometry of the final perovskite. With slightly prolonged deposition times, the start and end times are slightly less critical. This issue would be removed if the current batch process would be converted to a continuous process. Therefore, to enable better batch-to-batch reproducibility, a slightly longer reaction time is desirable. This is the reason why in this study, Tsource was kept maximum at 100 °C and three different conversion times were investigated, 25, 30, and 35 minutes.
Using the following settings, a gap of 1.4 mm, PbI2 at the substrate with a thickness of 200 nm, MAI as the source material, Tsource = 100 °C, and the three conversion times, different perovskite films were obtained. The films were characterized by XRD, optical absorption and scanning electron microscopy (SEM). Fig. 2a presents the XRD patterns for the three different conversion times: 25, 30, and 35 minutes. The XRD data show no peak at 12.5°, which corresponds to lead iodide, indicating the complete conversion of the inorganic precursor layer. This absence of residual lead iodide confirms that all three reaction times effectively transformed the material into the perovskite phase. The consistency in phase formation across different reaction times suggests that there is a wide window in the conversion process that allows for obtaining the perovskite films. These results highlight the efficiency of the method in achieving a fully crystallized perovskite structure. Fig. 2b presents the UV-Vis absorption spectra of the perovskite films prepared at the three different reaction times. The spectra exhibit a sharp absorption edge around 780 nm, characteristic of the MAPI perovskite. The nearly identical absorption profiles suggest that all three films have similar optical properties, indicating that the variations in reaction time do not significantly affect the light absorption behaviour of the material. This suggests that the CSS process allows flexibility in the conversion time with a window of conversion of at least 10 minutes. In the cross-section SEM image, Fig. 2c, we can observe the grain size and morphology of the perovskite film of a completed device obtained with the 30 minute process. The perovskite film has a uniform thickness of 370 nm with columnar grains that grow as thick as the perovskite film. The absence of voids or defects suggests good film quality and effective materials conversion. A representative top-view SEM image of the perovskite film is displayed in Fig. 2d. The surface morphology reveals grain sizes consistent with those observed in the cross-sectional analysis, with dimensions exceeding 200 nm. These grains are significantly larger than what is usually obtained for perovskites deposited using thermal co-sublimation in a high vacuum as shown in Fig. S6.23 To test the electrical properties of these thin films, we used the steady-state photo-carrier grating technique (SSPG),42 achieving an in plane minority carrier diffusion length of Ld ≈ 0.33 μm, which is on par with reported values for perovskite thin films.43,44 Co-sublimed MAPbI3 films fabricated during the same period exhibit slightly shorter diffusion lengths compared to those produced via the CSS method. This difference may be attributed to the larger grain sizes typically achieved with CSS, which can enhance charge transport. This effect is particularly relevant given that SSPG measurements probe in-plane diffusion lengths.
The CSS grown MAPI films were used to prepare fully-vacuum processed solar cells in a p–i–n configuration with the following structure: glass/FTO/MeO-2PACz/MAPI/C60/BCP/Ag, where C60 is fullerene and BCP is bathocuproine, which were used as electron transport layers (ETLs) and were deposited using thermal sublimation in a high-vacuum chamber. Ag was used as the top contact and the devices were encapsulated with Al2O3 using atomic layer deposition (ALD). Detailed information on device fabrication, characterization, and materials is included in the Experimental section.
Solar cells containing the three different perovskites, with the three processing times were characterized using current density voltage (JV) scans in the dark and under simulated AM1.5G solar illumination. The JV curves are displayed in Fig. S8 in the SI and the key performance parameters extracted from these JV curves are displayed in Fig. 3. While the results are rather similar, the 30 minute process stands out with the highest PCEs. The longer processing times are beneficial for the short-circuit current density (Jsc), with values of 21.9 and 21.8 mA cm−2 for the 30 and 35 minute processes, respectively. In contrast, shorter processing times lead to slightly better open-circuit voltage (Voc) and fill factor (FF), with the 25 and 30 minute samples outperforming the 35 minute process. Specifically, the Voc shows a difference of 35 mV between the shortest and longest times, while the FF shows an average improvement of 5–6%. Hence, the 30 minute process is the most suitable in terms of efficiency.
The external quantum efficiency (EQE), JV curve under 1 sun illumination and maximum power point (mpp) tracking of the best performing pixel of the devices processed for 30 minutes are displayed in Fig. 4. The data were obtained after having been stored for seven days under inert conditions, in ambient light and at room temperature. These conditions improve the performance slightly, something that we observed previously for co-evaporated perovskite-based devices.45 The EQE shows a plateau between 450 and 700 nm with values approaching 90%. The integrated current density calculated from the EQE spectrum is 23.6 mA cm−2, which is slightly higher than the value obtained from the JV curve under simulated solar illumination. This is somewhat opposite to the most general trend (Jsc from JV being higher), but not unusual and likely related to the very different light intensity used in the two measurements.46 In the region between 700 and 770 nm, the EQE slightly diminishes, due to the limited thickness of the perovskite film (370 nm extracted from the SEM cross-section). On the same graph the 1-R spectrum is represented, showing a 5% loss in reflectance and an offset of approximately 10% between EQE and 1-R, indicating losses in charge collection within the perovskite layer.47Fig. 4b shows the JV curve from the best pixel measured after 7 days. The performance improved reaching a PCE of 18.8%, Voc of 1.08 V, Jsc of 22.8 mA cm−2 and FF of 77%. The inset provides a magnified view of the stabilized power output, showing a stable power generation under steady-state conditions at 18.8%.
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| Fig. 4 (a) External quantum efficiency and 1-reflectance curves. (b) JV curve for the best pixel with stabilized power output measured for 100 s in the inset. | ||
Using the process described above (a working pressure of 1 mbar, source/substrate temperatures of 100/120 °C, and a conversion time of 30 minutes), we then went on to evaluate the prospect of our CSS method for larger-area perovskite deposition. In particular, we want to determine the pixel to pixel variation for 6 substrates (3 by 3 cm in size) that are simultaneously converted in our CSS system. In the previous devices an evaporated layer of MeO-2PACz was used with a thickness of 1.5 nm. This is a rather thin film and variations in its thickness lead to strong effects on the device performance. For this reason, we used an alternative hole transport layer that is less sensitive to the thickness variation. This HTL is a bilayer consisting of a 20 nm layer of a partially oxidized arylamine, N,N,N′,N′-tetra([1,1′-biphenyl]-4-yl)[1,1′:4′,1′′-terphenyl]-4,4′′-diamine (TATM) doped with the oxidant CS90112 covered by 10 nm of an intrinsic layer of TATM. This bilayer HTL has been used by our group in many previous reports.48 The details of the preparation of this layer are described in the Experimental section. Six substrates containing this bilayer HTL and a 200 nm layer of PbI2 were prepared and processed simultaneously under the same conditions with the CSS tool. After the conversion to perovskites, the stacks were completed into solar cells by the evaporation of C60/BCP and Ag as the ETL and top electrode, respectively (same as for the devices using the MeO-2PACz HTL).
Fig. 5a illustrates the positions of the six devices during the conversion process in the CSS system, numbered from 1–6. The corresponding device parameters are presented in Fig. 5b. All devices exhibited similar performance, with a mean PCE value of approximately 17.5% and a standard deviation of ±0.6. Voc values fluctuate slightly around an average of 1.09 V, with a deviation of ±0.01 V. Jsc shows minimal variations, averaging 20.2 mA cm−2 ± 0.3 mA cm−2. And the FF exhibits a slightly higher variability, averaging 78% ± 2%. The similarity of the power conversion efficiency (PCE) values to those of the top-performing pixel shown in Fig. 4 confirms the robustness of the process, underscoring its potential for high-throughput fabrication of large-area perovskite solar cells. Furthermore, negligible hysteresis was observed between the forward (negative-to-positive bias) and reverse JV scans, regardless of the scan rate employed (Fig. S9 and Table S1).
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| Fig. 5 (a) Bottom plate with the device layout of the six samples. (b) Performance statistics for the devices that have been converted: PCE, Voc, Jsc, and FF. | ||
The stability of the solar cells incorporating the bilayer hole transport layer (HTL) and the perovskite absorber fabricated via the CSS method was systematically evaluated. We employed a custom-built lifetime setup consisting of an LED array and a temperature-controlled hotplate to monitor the maximum power point (mpp) evolution of the CSS-fabricated devices over time (Fig. S10). As this system operates under ambient conditions, the solar cells were encapsulated using a UV curable resin and a top cover glass (Fig. S11). Copper wires were soldered to the contact pads prior to the application of the resin to enable contacting the individual pixels. This contacting and encapsulation procedure does not notably alter the performance of the cells, as verified by JV scans under simulated AM1.5G sunlight (Fig. 6a). The cells were maintained at maximum power point at 75 °C and at a light intensity equivalent to 1 sun.
Fig. 6a displays JV characteristics of a perovskite solar cell at different stages of encapsulation and thermal/light stress testing. The red curve represents the device performance as-deposited, while the pink curve shows the response after encapsulation, indicating minimal performance loss from the encapsulation process. Subsequently, the device was subjected to a maximum power point (mpp) tracking stability test at 75 °C under continuous 1 sun illumination. The dark blue curve corresponds to the JV measurements taken after 0 hours (t0) of mpp tracking operation; there was a loss in Voc when the solar cell was at elevated temperature despite the cell being freshly fabricated. This is expected from the diode equations and from the temperature coefficient of the Voc in perovskites, and also because the bandgap of perovskites increases with temperature.49
Fig. 6b shows the evolution of the normalized power output of the perovskite solar cells over more than 1000 hours under continuous mpp tracking at 75 °C and 1 sun equivalent illumination. The power output remains remarkably stable, with only a slight decrease over time. The normalized evolution of the Jsc and Voc extracted during mpp tracking is depicted in Fig. 6c. Negligible degradation in Voc and only a minor decrease over time in the Jsc were observed, indicating excellent operational stability under prolonged thermal and light stress. The minor fluctuations observed are within typical experimental variations, and the power output retains over 90% of its initial value, confirming the robustness of the device. This is one of the best reported stabilities for a MAPI-based solar cell, demonstrating the excellent properties of the CSS processed perovskite film.
Supplementary information is available. See DOI: https://doi.org/10.1039/d5el00145e.
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