The industrial deployment of organic photovoltaics (OPV) is currently constrained by various factors, such as the scalability of manufacturing techniques and the integration of OPV into practical applications [1]. One of the most effective methods for fabricating interconnections in OPV modules is short-pulse laser patterning [2], as this allows for high precision interconnections with minimum dead area in the module [3]. Nevertheless, this technique is challenging to optimize due to the wide variety of materials used in OPVs and the broad range of laser ablation parameters. The work presented here proposes a universal methodology to optimize the laser ablation parameters for a wide range of laser characteristics and materials. The methodology has been successfully tested with various materials in the OPV stack with nanosecond lasers, which, although more challenging to utilize than femtosecond lasers, offer greater industrial interest due to their lower cost [4]. Semitransparent OPV modules on both rigid and flexible substrates have been fabricated using laser ablation, with efficiencies reaching 4.3 % for a module area of 164 cm², underlining the promise of the technique for large-scale manufacturing and paving the way for further work to enhance the performance of these modules.

Additionally, the study addresses aspects related to the integration of OPV modules into plastic components, thereby enhancing their market value, potentially useful in different applications. The thermoplastic injection technique is employed to integrate the modules directly into plastic pieces. This process not only enables the 3D shaping of the modules, but it also imparts specific mechanical properties [5]. In this work we demonstrate for the first time the incorporation of new surface and optical properties to injection moulded OPV modules through micro and nanotexturing. First, we combine nanosecond laser ablation and thermoplastic injection to modify the surface properties of the OPV module. Microstructures are successfully replicated onto polycarbonate and polymethyl methacrylate plastic parts, and their properties are characterized by means of confocal microscopy, optical transmission, as well as contact angle measurements to confirm the enhancement in surface hydrophobicity from ~90º to ~135º. Then, light management nanotextures are successfully transferred to in-mold OPV modules, thereby enhancing their transmittance by 4.5 %.