Automated flexible solar cell fabrication and interconnection utilizing rolls expanded metallic mesh

A method for forming photovoltaic cells, comprising:

• (a) providing a first roll of a photovoltaic material and a second roll of an expanded metallic mesh, wherein the photovoltaic material comprises a photoactive material adjacent to a flexible substrate, and wherein the expanded metallic mesh comprises a plurality of openings;
• (b) providing an electrically insulating material adjacent to an edge portion of the photovoltaic material;
• (c) directing the photovoltaic material from the first roll and the expanded metallic mesh from the second roll into a vacuum drum and pressing the photovoltaic material against the expanded metallic mesh to form a nascent photovoltaic cell, wherein the electrically insulating material is disposed between the expanded metallic mesh and the photovoltaic material;
• and
• (d) cutting the nascent photovoltaic cell into individual sections to form a plurality of photovoltaic cells.