Abstract:In photovoltaic cell metallization, screen printing is predominantly employed due to its mature process. However, its complexity frequently results in silver paste waste, silicon wafer breakage, pollution, and significantly increased printing costs. The emerging laser transfer technology substantially reduces silver paste consumption by 20%-30% while enabling the transfer of ultra-fine grid lines below 16μm. Studies show that within screen printing, higher mesh counts enhance printing precision but increase silver paste penetration costs. Optimization of squeegee angle and pressure is found to reduce finger interruptions and paste overflow. Novel conductive pastes further enhance conductivity and printing precision. Laser transfer achieves precise and complete transfer of ultra-fine silver lines through the controlled adjustment of paste formulation, laser parameters, and receiving gap distance. Future development necessitates synergistic approaches: a hybrid process combining screen-printed busbars with laser-transferred fine grid lines in a stacked design is projected. This approach reduces cell shading loss from 3% to 1.2% while simultaneously enhancing photoelectric conversion efficiency. The integration and innovation of these technologies are expected to advance photovoltaic metallization towards greater efficiency, lower cost, and enhanced environmental sustainability, thereby supporting industry advancement.