Photovoltaic (PV) Solar Cell Manufacturing (Crystalline Silicon)

Solar Cell Manufacturing

PV (photovoltaic) solar cell manufacturing converts silicon wafers into finished solar cells that generate electricity. This step sits downstream of polysilicon, ingot, and wafer production, and upstream of module assembly. PV cells are where the functional conversion layer is created through diffusion, passivation, metallization, and testing. Cell manufacturing is capital intensive, yield sensitive, and often geographically concentrated.

PV cell technology overview

PERC (Passivated Emitter and Rear Cell): mature mainstream technology, increasingly replaced by newer architectures.
TOPCon (Tunnel Oxide Passivated Contact): higher efficiency and rapidly expanding production footprint.
HJT (Heterojunction): high efficiency, higher capex and process complexity.
IBC (Interdigitated Back Contact): premium architecture used by a smaller number of suppliers.

Where PV cells fit in the supply chain

Upstream: MG-Si > polysilicon > ingot > wafer
PV cell manufacturing: wafer processing into a finished solar cell
Downstream: module assembly (cells laminated into panels) > inverters > grid interconnection

Supply chain issues and constraints

Concentration: cell capacity has been highly concentrated in Asia, impacting regional supply independence.
Technology transitions: PERC > TOPCon/HJT shifts equipment needs and qualification requirements.
Yield sensitivity: small yield swings materially affect cost per watt at scale.
Policy and tariffs: cell sourcing is frequently shaped by trade rules and local-content incentives.

Worldwide PV cell manufacturing plants (starter list)

This table lists representative PV cell manufacturers and production footprints. Expand later with named factories, capacities, and technology lines (PERC, TOPCon, HJT, IBC).

Rank	Manufacturer	Location	Primary cell technologies	Notes
1	LONGi	China (multiple sites)	TOPCon and other lines	Major integrated PV manufacturer with large cell capacity.
2	Tongwei	China (multiple sites)	TOPCon and other lines	Global PV supply chain	Large cell manufacturer; also significant upstream presence.
3	JA Solar	China / SE Asia	PERC and TOPCon	Large cell and module supplier with diversified footprint.
4	JinkoSolar	China / SE Asia	TOPCon and other lines	Major global supplier transitioning toward newer cell architectures.
5	Trina Solar	China / SE Asia	TOPCon and other lines	Integrated PV supplier with large-scale manufacturing footprint.
6	First Solar	USA and global (multiple sites)	Thin-film (CdTe) modules (not c-Si cells)	Important US PV manufacturer; technology path differs from crystalline-silicon cell production.

U.S. PV cell production

Domestic PV manufacturing often emphasizes module assembly. PV cell manufacturing capacity in the U.S. is smaller and still scaling. This table lists notable US-based cell production initiatives and factories (including those pairing cell and module lines).

Rank	Manufacturer	Plant / Site	Location	Technology	Notes
1	Qcells	Integrated PV manufacturing buildout	Georgia	Crystalline silicon (cell + module chain)	Flagship US scaling effort; positioned as an integrated PV supply chain expansion.
2	Suniva (revival concepts)	PV cell facility footprint (historical)	Georgia	Crystalline silicon cells	Historically a US cell manufacturer; modern status depends on current ownership and investment.
3	First Solar	Thin-film PV factories (module-integrated)	Ohio / Alabama (and others)	Thin-film (CdTe) modules	Not crystalline-silicon cells, but a major domestic PV production pathway.

Market outlook

Cell manufacturing is the most strategically important step for PV supply chain independence. Regionalization depends on synchronized expansion across polysilicon, ingot/wafer, cell, and module steps. TOPCon and HJT transitions reshape equipment and supplier selection.

1) TOPCon and HJT expansion increases demand for new process tools and materials.
2) Domestic scaling requires local wafer supply or stable imports paired with US cell lines.
3) Cell manufacturing is sensitive to yield; quality systems and process control are primary competitive advantages.