AIKO presented its third-generation All Back Contact (ABC) architecture with zero-busbar (0BB) interconnection and improved micro-crack resistance
The company highlighted copper electroplating replacing silver in the contact base, stating that the process reduces thermal stress and supports mechanical stability
Scenario-based comparisons in C&I and utility projects indicated higher installed capacity within fixed footprints and LCOE reductions of up to 5.77%
As efficiency gains narrow across mainstream technologies, the focus is increasingly shifting toward how module design affects performance at the system level. Power density within a fixed footprint, temperature behavior, and resilience under partial shading are becoming key evaluation criteria, particularly in rooftop and land-constrained projects.
At the TaiyangNews High-Efficiency Solar Technologies Conference 2025, Guillermo Estébanez, Senior Product Solution Manager at AIKO, presented the company’s perspective on what he described as “The Era of Value Competition Driven by End-User Needs.” The discussion centered on refinements to AIKO’s All Back Contact (ABC) architecture and their impact at the system level.
The presentation focused on the company’s product level developments, including zero-busbar (0BB) interconnection, copper electroplating metallization, structural rear-side refinements supporting higher bifaciality, and validated improvements in thermal behavior under IEC stress testing.
Estébanez began by outlining the structural basis of AIKO’s All Back Contact (ABC) architecture. By relocating all current-collecting elements to the rear side of the cell, the design eliminates front-side busbars and reduces shading losses. According to the company, this increases active light absorption and improves incidence angle modifier (IAM) performance by up to 0.2% under IEC 61853 testing.
In mid-2025, AIKO introduced 0BB interconnection into mass production. By enabling direct current flow from fingers to soldering ribbons, the 0BB design shortens transmission distance and reduces resistive losses. AIKO stated that this contributes an additional 3-5 W in module output while increasing soldering points by approximately 10 times, a change presented as a measure to improve micro-crack resistance and long-term reliability.
Metallization was presented as another key differentiator within AIKO’s ABC platform. Estébanez explained that silver in the contact base is replaced with copper electroplating. Because the process does not require sintering, it avoids introducing additional thermal stress to the silicon wafer. Copper is used throughout the electrical circuit, including both fingers and ribbons, with reported tensile strength exceeding 5 N. To further address mechanical stress, AIKO uses single-side soldering instead of traditional Z-shaped overlap soldering, which is reported to reduce stress concentration during welding.
Beyond metallization, the third-generation structure incorporates additional refinements. These include reduced finger width, adjustments to N- and P-region electrode spacing, reduced N-poly thickness, evolution from MBB to SMBB and now to 0BB interconnection structures, and partial rear-side texturization. Bifaciality levels above 80% were reported for the latest generation modules.
Estébanez then addressed module thermal behavior and electrical performance, presenting results from standardized IEC testing. Under enhanced hot-spot cycling in accordance with IEC 61215-2:2021 MQT 09, AIKO’s BC modules were reported to operate more than 35% cooler than TOPCon reference modules.
In diode thermal testing under IEC 61730-2 MST 13, diode temperatures were reported to be 14% lower. Reverse current overload testing under IEC 61215-2:2021 MQT 21 showed cell temperatures 15% lower under the same comparison conditions.
The temperature coefficient is specified at -0.26%/°C, with first-year degradation at ≤1% and annual degradation of 0.35%. Under full-cell shading conditions, a 30% higher power output was reported compared to conventional modules.
AIKO’s third-generation BC modules, under the Infinity brand, are based on its ABC architecture. AIKO ranked first in the TaiyangNews Top Solar Modules listing, with the company’s 670 W product listed at 24.8% module efficiency (see TOP SOLAR MODULES Listing – February 2026).
In the residential segment, NeoSTAR modules are offered in 54- and 60-cell configurations, with power classes ranging from 465 W to 545 W depending on format. For commercial and industrial (C&I) applications, AIKO promotes NeoSTAR modules in 54- and 60-cell configurations, alongside larger 72-cell Comet 3N72 and Stellar 3N+72 formats. In the configurations shown, power classes extend up to 690 W, with both dual- and mono-glass options presented for white-back designs.
For utility-scale projects, AIKO offers the larger-format Stellar series modules in 66- and 78-cell layouts. The 66-cell version is rated up to 690 W, while the 78-cell configuration reaches up to 805 W. The utility formats reach module bifaciality of 80 ± 5%, together with a temperature coefficient of -0.26%/°C and first-year degradation of ≤1%.
To demonstrate the system-level implications, AIKO presented a comparative scenario for a C&I rooftop installation in the Netherlands. The available roof area was fixed at 3,422 m², with 1,188 modules installed in both configurations.
The analysis compared 505 W conventional modules with 535 W ABC INFINITE modules of identical dimensions (1,954 × 1,134 mm). Within the same footprint, installed capacity increased from 600 kWp to 636 kWp.
Annual energy production increased from 517 MWh to 576 MWh, a difference of 59 MWh. Specific yield rose from 862 to 905 kWh/kWp per year, representing a 4.8% increase. The payback period was approximately 2 months shorter under the ABC configuration.
Utility-scale simulations were presented for a 50 MW project in Cuenca, Spain, with land area fixed at 37.38 hectares and a 2P28 mounting system at 0° azimuth orientation.
In a fixed-capacity scenario, using 670 W ABC modules instead of 630 W conventional modules enabled pitch to increase to 8.1 m, more than 0.6 m higher than the reference layout. Energy production over 30 years increased by 3.59%, with balance-of-system savings estimated at €0.011 /W. LCOE decreased from 0.3417 to 0.3315, representing a 5.77% reduction.
In a second configuration within the same land footprint, DC capacity increased from 50 MW to 53 MW. Energy production over 30 years increased by 6.80%, balance-of-system savings were estimated at €0.015 /W, and LCOE decreased from 0.3417 to 0.3271, corresponding to a 4.22% reduction.
The full presentation is available on the TaiyangNews YouTube channel here.