Life-Cycle Assessment of Innovative Industrial Processes for Photovoltaic Production: Process-Level LCIs, Scale-Up Dynamics, and Recycling Implications

The rapid commercialization of next-generation photovoltaic (PV) technologies, particularly perovskite, thin-film roll-to-roll (R2R) architectures, and tandem devices, requires robust assessment of environmental performance at the level of industrial manufacturing processes. Environmental impacts can no longer be evaluated solely at the device or module level. Although many life-cycle assessment (LCA) studies compare silicon, cadmium telluride (CdTe), copper indium gallium selenide (CIGS), and perovskite technologies, most rely on aggregated indicators and database-level inventories. Few studies systematically compile and harmonize process-level life-cycle inventories (LCIs) for the manufacturing steps that differentiate emerging industrial routes, such as solution coating, R2R processing, atomic layer deposition, low-temperature annealing, and advanced encapsulation–metallization strategies. In addition, inconsistencies in functional units, system boundaries, electricity-mix assumptions, and scale-up modeling continue to limit meaningful cross-study comparison. To address these gaps, this review (i) compiles and critically analyzes process-resolved LCIs for innovative PV manufacturing routes across laboratory, pilot, and industrial scales; (ii) quantifies sensitivity to scale-up, yield, throughput, and electricity carbon intensity; and (iii) proposes standardized methodological rules and open-access LCI templates to improve reproducibility, comparability, and integration with techno-economic and prospective LCA models. The review also synthesizes current evidence on recycling, circularity, and critical-material management. It highlights that end-of-life (EoL) benefits for emerging PV technologies are highly conditional and remain less mature than for crystalline-silicon systems. By shifting the analytical focus from technology class to manufacturing process and life-cycle configuration, this work provides a harmonized evidence base to support scalable, circular, and low-carbon industrial pathways for next-generation PV technologies.