Recent research recruitment
Two postdoctoral positions in advanced PV technology were recently advertised, supporting silicon-cell and module manufacturing research.
Metallisation & Sustainability Group · UNSW
Sustainable solar-cell manufacturing.
A UNSW research group advancing silver-lean contact structures, silicon-cell reliability and resource-efficient photovoltaic manufacturing.
Research contribution
Silver-lean contact design
The design map shows how reducing silver-contact area and print height creates a practical pathway from 12.6 mg/W towards 5 and 2 mg/W.
PhD opportunities
Strong candidates are welcome year-round across PV materials, metallisation, reliability and advanced manufacturing.
Two ARENA projects announced ↗
A$9.8M in ARENA funding for low-temperature PV interconnection and site-tailored solar modules.
Research & industry collaboration
We welcome partnerships with cell manufacturers, materials and equipment suppliers, and research organisations.
U.S. patent granted for dash (seed-layer) contact IP ↗
A U.S. patent has been granted for the team’s low-silver metallisation architecture using discrete dash (seed-layer) contacts beneath conductive fingers.
PV sustainability
Brett Hallam PV Sustainability Lab.
Reducing material use while improving conversion efficiency, reliability and economic value across photovoltaic manufacturing.
Efficiency × manufacturing cost
Efficiency sets how many watts each square metre of module delivers. Only when higher output and lower manufacturing cost bring the cost per watt below the market price does a technology earn a margin. In the chart, TOPCon (set to 100) sits on that line, and other technologies are read relative to it. That line is the manufacturer’s lifeline, and cutting metal use is one of the few levers that moves a product across it.
Metal intensity across PV
Historical estimates, independent benchmarks and projections use different models. Sources: CRU / Silver Institute 2020 (Ag per cell 2009–2019, converted at typical cell power); IEA Global Critical Minerals Outlook 2026; Carrara et al., JRC 2020 (2018 baseline, 2030/2050 scenarios); Zhang et al., Energy Environ. Sci. 2021 (2 mg/W target); Kim et al., APVI 2024 (EPD frame average); ITRPV 17th ed. Estimated points scale the 2018 value by average module efficiency (16.0% in 2013, JRC 2024). The cell panel uses a logarithmic axis.
Sources
Historical estimates, independent benchmarks and projections use different models. Sources: CRU / Silver Institute 2020 (Ag per cell 2009–2019, converted at typical cell power); IEA Global Critical Minerals Outlook 2026; Carrara et al., JRC 2020 (2018 baseline, 2030/2050 scenarios); Zhang et al., Energy Environ. Sci. 2021 (2 mg/W target); Kim et al., APVI 2024 (EPD frame average); ITRPV 17th ed. Estimated points scale the 2018 value by average module efficiency (16.0% in 2013, JRC 2024). The cell panel uses a logarithmic axis.
Use less material.
Explore lower metal intensity at the cell, module and system levels.
Keep solar power durable.
Connect new processes with efficiency and long-term reliability.
Industry technology watch
Research directions moving into manufacturing.
Public industry disclosures show how layered contacts, reduced contact area and abundant conductive materials are entering high-volume photovoltaic manufacturing.
A silver contact layer beneath an Ag–Cu conductor
Publicly available data indicates a layered TOPCon electrode: a thin silver contact layer forms the silicon contact, while an overlying silver-coated copper layer provides bulk conduction. Laser-assisted firing supports contact formation at a lower thermal budget.
Why it matters
Read source↗The functional separation between contact formation and current transport closely parallels seed-layer metallisation research.
Nano-alloy matrix contact enters mass production
LONGi describes ACM as a silver-free nano-alloy contact that separates a small-area current-collection layer from a high-conductivity transmission layer. Industry reporting further characterises the stack as a seed or barrier layer coupled to a copper-based alloy conductor.
Why it matters
Read source↗The architecture independently demonstrates the industrial value of separating interface contact from high-conductivity current transport.
Summaries are based on publicly available industry and patent information. Similarities in technical direction do not imply licensing, technology transfer or use of UNSW intellectual property.
People
Research leadership
The group brings together expertise in silicon photovoltaics, metallisation, reliability and technology translation.
Research lead · Professor · Leading researcher in photovoltaic manufacturing and technology translation
Brett Hallam
Brett leads research on sustainable photovoltaic manufacturing, advanced cell architectures, hydrogen passivation, laser processing and material constraints at scale.
View UNSW profile↗
Technology translation & reliability lead · ACAP Fellow · Senior Lecturer · Senior Researcher
Catherine Chan
Catherine works across industrial silicon solar cells, laser processes, hydrogen passivation, degradation control and technology translation.
View UNSW profile↗
Research & partnerships · ACAP Fellow · Senior Lecturer · Senior Researcher · SPREE Outreach & Student Recruitment Lead
Li Wang
Sustainable PV materials & metallisation · Industry translation · Ultra-thin silicon PV
View UNSW profile↗Research team
Team researchers
Researchers across the team contribute expertise in photovoltaic sustainability, silicon reliability, industrial processing and advanced photovoltaics.
Research & industrial impact
From laboratory process to manufacturing relevance.
From Brett Hallam’s research in solar-cell engineering to industrial partnerships and pilot production, the programme connects scientific advances with manufacturing practice.
Research leadership · Industry translation
Brett Hallam: connecting solar science with manufacturing
Recognition
NSW Premier’s Prize for Energy Innovation
Brett Hallam received the Energy Innovation award at the NSW Premier’s Prizes for Science and Engineering. The recognition highlighted his work on controlling hydrogen in silicon to neutralise defects, improve solar-panel output and enable lower-cost solar electricity.
Green TalentsRead the original story↗
Research
News & activities
Research in motion
Publications, conferences, project milestones and news from across the group’s research programme.
Low-temperature interconnection for advanced PV modules
A$5.4M ARENA funding (A$12.4M total project). Developing bismuth-lean interconnection, low-temperature silver-free metallisation and curing processes with industry partners.
View ↗Site-tailored modules for lower-cost solar deployment
A$4.4M ARENA funding (A$13.9M total project). Optimising modules for local climate, system design and electricity markets, with prototype testing and a target of at least 1% lower system LCOE or higher project NPV.
View ↗U.S. patent granted for dash (seed-layer) contact metallisation
U.S. patent granted for Metallization for silicon solar cells (application 18/278,256, published as US 2024/0136449 A1), covering discrete dash (seed-layer) contacts beneath conductive fingers and material combinations designed to reduce silver use while preserving electrical performance.
View ↗More research updates
Join & collaborate
Scholarship-supported PhD opportunities.
Scholarship-supported PhD opportunities are available for strong candidates, subject to UNSW HDR admission and scholarship requirements.
01Scholarship-supported PhD positions
Build the next generation of solar-cell manufacturing.
We are recruiting PhD candidates for research that connects materials, solar-cell architecture, device analysis and industrial manufacturing.
Apply now↗Send an expression of interest and attach your CV as a PDF.
Please send your CV to: li.wang3@unsw.edu.au
Explore research themes
01Silver-lean metallisation+
Fine-line printing, seed-layer contacts, low-silver pastes and copper-enabled contact structures for industrial silicon solar cells.
02Cell structures & contacts+
Advanced silicon cell architectures, interface contact engineering and manufacturing-compatible process integration.
03Loss analysis & characterisation+
Identify electrical, optical and reliability losses using device analysis and process-informed characterisation.
04Efficiency & manufacturing+
Efficiency improvement, laser and thermal processing, process windows and translation to production-relevant equipment.
Research & collaboration
Contact us
For research collaboration, industry enquiries and potential projects, please contact Li Wang.
Research & industry enquiries
li.wang3@unsw.edu.au↗Li Wang
ACAP Fellow · Senior Lecturer · Senior Researcher · SPREE Outreach & Student Recruitment Lead