Scalable fabrication of high-performance organic solar cell modules: from materials to manufacturing

molecular engineering, additive selection, and green solvent systems facilitates uniform film formation and optimized phase separation. Furthermore, large-area coating techniques such as blade coating, slot-die coating, and roll-to-roll printing, combined with advanced annealing and laser patterning, have significantly improved large-area organic solar module performance and consistency. Key challenges including material cost, morphological instability, and process reproducibility are critically discussed. Future perspectives on high-throughput material screening, AI-assisted molecular design, and industrial-scale integration are also presented, aiming to accelerate the commercialization of large-area OSCs.