Zero-Busbar (0BB) module technology is rapidly emerging as a key advancement in the photovoltaic industry as manufacturers push for higher efficiency, lower material usage, and improved module reliability. Traditional solar cells have long depended on multiple busbars to collect current, but these wide metallic strips introduce shading losses, increase silver consumption, and contribute to solder-related stress on the wafers. By eliminating these busbars entirely, 0BB technology unlocks more active surface area, streamlines current flow, and supports more mechanically stable module architectures.

In a 0BB design, current is collected directly through ultra-fine metallization fingers on the cell surface. These fingers are linked to the module’s interconnection system using conductive adhesives, structured ribbons, or wire-based micro-ribbons. This busbar-less architecture not only enhances light absorption but also lowers series resistance due to shorter current paths. As a result, modules typically exhibit higher fill factor, improved power output, and more uniform performance across production batches. Removing busbars also leads to notable silver paste savings—which contributes directly to lowering the overall cost per watt.

From a mechanical perspective, 0BB technology is well suited for the industry-wide trend toward thinner silicon wafers. Instead of relying on soldered joints, which can cause stress, bowing, or crack propagation, 0BB modules often use low-temperature conductive adhesives that distribute mechanical load more evenly. This results in better long-term reliability, reduced micro-crack development, and enhanced module durability during thermal cycling, damp heat exposure, and mechanical load testing. The distributed nature of the current collection also reduces the likelihood of hotspot formation, contributing to more stable field performance.

Despite its advantages, 0BB technology does come with challenges. Ultra-fine fingers are more sensitive to breakage, and many existing stringing machines are not compatible with busbar-less interconnection without modification or replacement. Although silver usage decreases, the cost of conductive adhesives or advanced ribbons can partially offset savings, requiring careful bill-of-material (BOM) optimization. Even with these challenges, industry momentum is building quickly. Top global manufacturers are already integrating 0BB or hybrid busbar-less architectures into their TOPCon, HJT, and next‑generation tandem modules, recognizing the significant efficiency and reliability benefits.

In a nutshell, Zero-Busbar technology represents a clear and meaningful step toward next‑generation photovoltaic modules. By removing busbars and adopting advanced interconnection strategies, module makers can deliver superior electrical performance, improved mechanical resilience, and reduced material usage—all essential factors as the industry moves toward multi‑terawatt global deployment. With its compatibility across modern and future cell technologies, 0BB stands out as a forward‑looking solution that aligns with the sector’s long‑term goals for sustainability, efficiency, and scalability.

Source: R&D Dept. WAAREE Energies Ltd.