Startup Aims to Cut the Cost of Solar Cells in Half

Technology Review
March 13, 2012

Flexible power: Twin Creeks’s 20-micrometer-thick metal-coated silicon wafers are flexible and strong.

Twin Creeks Technologies—a startup that has been operating in secret until today—has developed a way to make thin wafers of crystalline silicon that it says could cut the cost of making silicon solar cells in half. It has demonstrated the technology in a small, 25-megawatt-per-year solar-cell factory it built in Senatobia, Mississippi.

Siva Sivaram, the CEO of Twin Creeks, says the company's technology both reduces the amount of silicon needed and the cost of the manufacturing equipment. He claims the company can produce solar cells for about 40 cents per watt, which compares to roughly 80 cents for the cheapest solar cells now. Twin Creeks has raised $93 million in venture capital, plus loans from the state of Mississippi and other sources that it used to build its solar factory.

The conventional way to make the crystalline silicon wafers—which account for the bulk of solar cells—involves cutting blocks or cylinders of silicon into 200-micrometer-thick wafers, a process that turns about half of the silicon into waste. The industry uses 200-micrometer wafers because wafers much thinner than that are brittle and tend to break on the manufacturing line. But in theory, they could be as thin as 20 to 30 micrometers and still be just as efficient, or more efficient, at converting sunlight into electricity.
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