Reducing Cost of Space Photovoltaics via Sound-Assisted Substrate Reuse

High substrate costs limit the proliferation of many next-generation semiconductor device applications, such as high-efficiency GaAs-based photovoltaics for space applications, often consuming 50% of the cell manufacturing cost. We propose a novel substrate re-use technology, known as Sonic Lift-off (SLO) to drive down the costs of space photovoltaic manufacturing. SLO utilizes sound to separate thin devices from their host substrate, leaving the remaining substrate available for multiple reuses. A key milestone in the march towards commercialization is the ability to demonstrate the technology at industrially relevant wafer diameters. In this proposal we plan to build upon our successes to date demonstrating 2" diameter wafer SLO and extend this to 4" wafer diameters with improvements to our SLO instrumentation and process control.

NASA benefits: Substrate re-use of GaAs photovoltaic devices for space. Non-NASA benefits: A wide range of emerging next-generation semiconductor device technologies based on 'wide bandgap' semiconductors, including SiC, GaN, AlN and others. Applications include: power electronics for electric vehicles, electric motors, photovoltaic inverters and more; RF communication devices; UVC-LED devices for disinfection; Laser diodes and sensor applications and more.

This is early/mid-stage (TRL 5) — the most realistic path in is NASA SBIR/STTR, which funds small businesses and research institutions to develop technology aligned with NASA's needs (equity-free, phased funding). Check whether a current SBIR/STTR solicitation topic overlaps with this project's technology area, or contact the project directly (above) to ask.

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