Highly efficient, large area, roll coated flexible and rigid OPV modules with geometric fill factors up to 98.5% processed with commercially available materialsElectronic supplementary information (ESI) available. See DOI: 10.1039/c5ee03315b

Highly efficient, large area OPV modules achieving full area efficiencies of up to 93% of the reference small area cells are reported. The way to a no-loss up-scaling process is highlighted: photoelectrical conversion efficiencies of 5.3% are achieved on rigid modules and of 4.2% on flexible, roll coated ones, employing a commercially available photoactive material. Exceptionally high geometric fill factors (98.5%), achieved via structuring by ultrashort laser pulses, with interconnection widths below 100 μm are demonstrated. Flexible roll-coated and rigid organic PV modules, solution processed on a large area, are reported with efficiencies of 4.2% and 5.3%, respectively.