A pioneering project led by Fraunhofer ISE has resulted in the development of a new micro-concentrator photovoltaic (micro-CPV) module. This innovation uses advanced microfabrication techniques to increase solar efficiency while reducing material use and production costs. The result is a compact solar technology suitable for applications in sustainable architecture, product design, mobility, and smart packaging.

Pushing Efficiency with Smart Miniaturisation

Concentrator photovoltaics (CPV) are among the most efficient solar technologies available. They work by focusing sunlight onto small, high-performance III-V multi-junction solar cells. The micro-CPV project builds on this principle using technologies from microelectronics and display manufacturing. These include additive manufacturing, precision miniaturisation, and self-alignment.

Thanks to these advances, the modules can concentrate sunlight by a factor of 1,000. This reduces the area needed for active solar material and makes it possible to use expensive but highly efficient cells. The reduction in semiconductor material is substantial—up to 1,300 times less than that used in traditional silicon solar panels.

High Performance in a Compact Format

The research team created a demonstrator module with 60 tiny lens-cell units and an aperture area of 205 cm². Each solar cell is just a fraction of a square millimetre. These are positioned onto a glass base with exceptional precision.

Despite the compact design and high concentration of sunlight, the module operates at safe temperatures. This is possible because the small cells dissipate heat effectively, even without a dedicated heat sink. The module achieved a certified efficiency of 36% under standardised testing, which confirms its strong performance.

Scalable Design with Real-World Potential

The flat, lightweight format of the micro-CPV modules makes them ideal for design integration. They are suitable for solar façades, autonomous devices, mobility applications, or even advanced packaging solutions.

To move toward commercialisation, the team scaled up the module to a standard 24″×18″ panel format, commonly used in the printed circuit board industry. Outdoor field testing of these panels is underway.

In addition, the team developed a detailed model to evaluate how small manufacturing variations affect module performance. These insights help identify which tolerances can be relaxed for cost benefits without sacrificing quality.

A Step Forward in Circular Solar Design

This project demonstrates how smart manufacturing can enhance both performance and sustainability. Designers in architecture, mobility, and product innovation now have access to a new option for integrating clean energy into their work.

By using fewer materials, streamlining production, and offering a high energy yield, micro-CPV technology aligns well with circular design principles. A spin-off company is currently being prepared to bring the product to market.

Source: Fraunhofer ISE
Photos: Fraunhofer / Elisa Kaiser / Dirk Mahler / Wagenbrett GmbH & Co. KG