Key takeaways:
TNO developed a laser-assisted PV recycling process to separate encapsulants from solar cells without damaging the module layers
The process uses localized heating to loosen adhesion, enabling intact recovery of glass and cells with lower energy consumption
The technology has been tested on multiple module types and is being scaled toward industrial recycling applications
Recycling PV modules is not an easy task because of the panel’s sturdiness, all thanks to the encapsulant. While there are several ways to recycle a PV module, the efficiency and quality of the recovered materials vary by process. Mechanical crushing of modules not only destroys the whole assembly but also makes the extraction of valuable materials, such as silver and silicon, hard or energy-intensive. Other methods include thermo-mechanical, thermal, and chemical methods, which differ in scaling or throughput, investment costs, and, most importantly, the quality of recovered materials.
Novel methods use lasers to recycle PV, reducing overall costs and improving the efficiency and quality of the materials recovered. TNO (Netherlands Organization for Applied Scientific Research) has developed a laser solution to efficiently dismantle solar panels without damaging the cells within. The illuminated laser is configured to heat the target area to a desired temperature, which in this case is most likely the solar cell. This heat loosens the adhesion between the cell and the encapsulant, enabling the separation of the 2 materials. This way, the layers are separated without further heating or chemical treatment.
With this approach, the glass and the cells remain intact after dismantling. According to the press release, the entire process uses less than 1 kWh of energy per module. Compared with other techniques, such as pyrolysis, which require about 25 kWh per module, this represents a fraction of the energy consumption.
Mirjam Theelen, Research Leader at TNO, says, “With laser-based techniques, we show that recycling can be done differently: energy-efficient and while preserving value.”
The team published its work at the end of 2025, in which a picosecond-pulsed near-infrared laser was used to weaken the adhesion between the silicon wafer and the encapsulant, completely separating them in a thermomechanical step.
The research team at TNO has been working on this technology for 3 years. According to the press release, almost all types of solar panels have already been successfully disassembled with this method. An advantage of this approach is that the weakening of adhesion is visible in real time, with a subtle color change. This phenomenon helps with the feedback and supports further tuning of the process.
The press release states that this process has now been scaled up for industrial use, and future work focuses on integrating this technology into the PV recycling process chain.
Theelen further adds, “This laser technology yields a goldmine of raw materials. After all, a significant amount of discarded solar panels is expected in Europe by 2030. A unique economic opportunity.”