Cu2ZnSnS4(CZTS) thin films and solar cells were successfully prepared using a new process based on spray pyrolysis technique. The main advantage of the proposed process is the avoiding of sulphurisation process at high temperature and in toxic gases like H2S. X-ray diffraction studies and Raman spectroscopy confirmed the formation of good-quality microcrystalline CZTS films in a tetragonal structure. Optical measurements showed that CZTS films have a direct band gap and high absorption coefficient (4 × 104 cm−1) as requested for solar cell application. CZTS solar cell prototypes deposited on low-cost flexible plastic substrates were prepared and tested. [ABSTRACT FROM PUBLISHER]