AI is helping bring perovskite solar cells closer to sustainable commercialization, according to a new study from researchers in South Korea. Published in Green Chemistry and featured on the journal’s cover, the research presents a comprehensive roadmap that combines artificial intelligence with eco-friendly manufacturing processes to overcome major barriers in the development of next-generation solar technology. Perovskite solar cells are known for their high theoretical efficiency—up to 34%—which exceeds that of conventional silicon-based solar cells. However, their widespread adoption has been limited by two key challenges: the use of toxic solvents like dimethylformamide (DMF) in production and poor long-term stability. A team led by Professor Jeehoon Han from the Department of Chemical Engineering at POSTECH (Pohang University of Science and Technology) collaborated with Professor Min Kim from the University of Seoul to develop a greener alternative. They introduced a new fabrication process using bio-based solvents—gamma-valerolactone (GVL) and ethyl acetate (EA)—instead of harmful DMF. At the heart of the innovation is AI-driven reverse engineering. The researchers used machine learning to analyze experimental data and identify optimal manufacturing conditions that simultaneously improve efficiency, reduce costs, and lower environmental impact. These AI-generated predictions were then validated through real-world experiments. The team also developed a sustainability evaluation model that accounts for manufacturing expenses, carbon emissions, process efficiency, and long-term performance. They further integrated a global deployment scenario to assess how the technology could be scaled across different regions. The results were striking. The GVL-EA process reduced manufacturing costs by 50% and cut climate impact by more than 80% compared to traditional methods. The study also showed that factoring in module lifespan and recycling strategies is essential for determining the true break-even point for commercialization in various markets. Professor Han emphasized the transformative role of AI, noting it identified viable conditions that were previously thought unattainable. He added that replacing toxic solvents with safe, renewable alternatives makes perovskite solar cells not only more efficient and cost-effective but also significantly safer for people and the planet. This breakthrough marks a major step toward making perovskite solar cells a practical, sustainable energy solution on a global scale.