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We demonstrate the fabrication of polymer solar cells in which both a PEDOT:PSS hole transport and a PCDTBT:PC71BM photoactive layer are deposited by spray-casting. Two device geometries are explored, with devices having a pixel area of 165 mm2 attaining a power conversion efficiency of 3.7%. Surface metrology indicates that the PEDOT:PSS and PCDTBT:PC71BM layers have a roughness of 2.57 nm and 1.18 nm over an area of 100 μm2. Light beam induced current mapping reveals fluctuations in current generation efficiency over length-scales of ∼2 mm, with the average photocurrent being 75% of its maximum value

Polymer-based solar cells having an active area of 1.6 cm2 fabricated via spray coating