Photovoltaic (PV) cells convert sunlight to electricity. Crystalline silicon was the original materials technology used by the PV industry. First widely used in space satellites, conventional crystalline silicon solar cells are fabricated in a step-and-repeat, batch process from small wafers of single crystal or polycrystalline silicon semiconductor materials. Although, substantial advances have been made in the development of this technology, the cost of crystalline PV modules is still high because of materials costs and numerous processing steps that are needed to manufacture the modules. Crystalline silicon solar modules are bulky, break easily, and consume more energy in manufacturing.
Another thin-film technology for producing solar cells contains cadmium. Not environmentally friendly, and requiring great care be taken during manufacturing and after sale. These thin-film technologies, as well as crystalline silicon technology, employ a step-and-repeat batch process, not a continuous roll-to-roll manufacturing process like our amorphous silicon.

Using our proprietary thin-film, vapor-deposited amorphous silicon (a-Si) alloy materials, we have developed proprietary technology to reduce the materials cost in a solar cell. Because a-Si absorbs light more efficiently than its crystalline counterpart, the a-Si solar cell thickness can be 100 times less, thereby significantly reducing materials cost. By utilizing a flexible, stainless steel substrate and polymer-based encapsulates, PV products utilizing our technology can be very lightweight, flexible and durable. No broken parts during shipping and easy to transport to remote rural areas, thus saving shipping costs, and can be installed without breakage.

Amorphous cells with different light absorption properties deposited continuously, one on top of another, to capture the broad solar spectrum more effectively. This increases the energy conversion efficiency of the multi-cell device and improves performance stability. Our unique multi-junction approach has resulted in world record efficiencies for our a-Si technology.
We hold the current world records for both large- and small-area conversion efficiency for a-Si solar cells, as measured by the DOE's National Renewable Energy Laboratory (NREL).

To further reduce the manufacturing cost of PV modules, we have pioneered the development of and have the fundamental patents on a unique approach utilizing proprietary continuous roll-to-roll solar cell deposition process. Using a roll of flexible stainless steel that is a half-mile long and 14 inches wide, nine thin-film layers of a-Si alloy are deposited sequentially in a high yield, automated machine to make a continuous, three-cell stacked structure. The roll of solar cell material is processed further for use in a variety of photovoltaic products. This basic approach, pioneered by us, is unique in the industry and has significant manufacturing cost advantages. We believe that with continuing improvement in technology and high-volume production, our PV modules will be significantly less expensive than conventional crystalline silicon and other thin-film solar modules produced on glass, and will be cost competitive with fossil fuels.

We have an annual production capacity of 5MW that is now being expanded to 30MW by the addition of a new facility located in Auburn Hills, MI. This plant is fully automated and allows simultaneous processing of six rolls of stainless steel, each 1 1/2 miles long, during deposition of the a-Si layers.