We study the fabrication of poly(3-hexylthiophene)-P3HT and [6,6]-phenyl-C61 butyric acid methyl ester-PCBM based polymer bulk heterojunction photovoltaic cells using rotogravure printing. By studying the dependencies of device performance on material and process parameters including contact angles, ink concentrations, ink viscosities, solvent characteristics, and gravure printing parameters, optimized hole transport layers [poly(3,4-ethylenedioxythiophene):poly(styrenesulfonate)-PE-DOT:PSS] and active layers (P3HT:PCBM) are printed. resulting in devices with power conversion efficiencies as high as 1.68% under AM 1.5 G and a spectrally matched intensity of 100 mW/cm(2). (C) 2008 Elsevier B.V. All rights reserved.